Archive for 2016

Low Cab Forward Medium-Duty Trucks

The all-new Low Cab Forward medium-duty trucks are the latest in a long line of Chevrolet models in the commercial market. (Fig. 1) The seven new Low Cab Forward models, offered in regular cab or crew cab body styles, are the 3500, 3500HD, 4500, 4500HD, 4500XD, 5500HD and 5500XD. The trucks area available with a variety of upfit equipment and bodies provided by independent suppliers.


F01 LCF trucks 1

Fig. 1


Depending on the model, the trucks are equipped with either a GM 6.0L V8 gasoline engine, a GM 6.0L V8 LPG/CNG-capable engine, or an Isuzu 3.0L or 5.2L I4 turbocharged diesel engine.




3500 and 4500 Configurations


Available in regular cab and crew cab configurations, the 3500 and 4500 models are equipped with a Vortec 6.0L V8 engine (RPOs L96, LC8) and mated to a Hydra–Matic 6L90 6-speed automatic transmission (RPO MYD).


3500HD Configuration


The 3500HD truck is equipped with an Isuzu 3.0L I4 turbocharged engine (RPO IZ3) and an Aisin A460 6-speed automatic transmission (RPO IX0). It’s available in a regular cab configuration.


4500HD and 4500XD Configurations


The 4500HD and 4500XD models are equipped with an Isuzu 5.2L I4 turbocharged engine (RPO I1B) with an Aisin A465 6-speed automatic transmission (RPO IR7). These models are available in regular cab and crew cab configurations.


5500HD and 5500XD Configurations


The 5500HD is available in regular cab and crew cab configurations while the 5500XD is available as a regular cab model. These trucks are equipped with an Isuzu 5.2L I4 turbocharged engine (RPO I1B) and an Aisin A465 6-speed automatic transmission (RPO IR7).




Regular cab models equipped with 6.0L V8 gasoline or LPG/CNG engines – The engine oil dipstick can be found on the left side of the engine after tilting the cab.


Crew cab models equipped with 6.0L V8 gasoline or LPG/CNG engines – The engine oil dipstick is under the engine inspection sub-cover underneath the passenger seat. Use the strap on the front of the seat to raise the seat cushion. Release the sub-cover catch hooks to raise the cover for access to the oil dipstick.


Regular and crew cab models equipped with 3.0L I4 or 5.2L I4 diesel engines – The engine oil level can be checked using the oil level switch on the left side of the instrument panel. (Fig. 2) When checking the oil level, be sure the vehicle is on level ground and the engine is cool. Press the engine oil level check switch on the instrument panel. If the oil level is low, the red oil pressure warning light will turn on. If the engine oil level is acceptable, the green oil level indicator will turn on. The oil level also can be checked using the oil level dipstick.


F02 LCF button 3

Fig. 2




Diesel Engine Coolant


The diesel engines use a long-life coolant that is green in color. The addition of conventional green propylene glycol coolant will damage the engine. The factory-installed long-life green engine coolant is not available from GM Customer Care and Aftersales. Use only yellow long-life coolant (GM P/N 12378560; ACDelco P/N 10-5034) in the Low Cab Forward diesel engines. It is the only product that has been certified as compatible with the original long-life green diesel engine coolant.


A fuel system cooler (Fig. 3) has been added to models equipped with the 5.2L I4 diesel engine. The fuel system cooler compensates for increased fuel pressure and increased cylinder pressure due to changes in the camshaft timing, which results in higher fuel temperatures. The cooler reduces the fuel temperature prior to the fuel returning to the fuel tank. The cooler is mounted in front of the rear axle.


F03 LCF cooler 5

Fig. 3


Diesel Emission Systems


The 3.0L and 5.2L diesel engines use a Diesel Particulate Filter (DPF) system with a Diesel Oxidizing Catalyst (DOC) and a Selective Catalytic Reduction (SCR) assembly to meet current diesel emissions standards. (Fig. 4)


F04 LCF emission sys 6

Fig. 4


The DPF system that is designed to capture particulate matter (PM), or soot, is the same on both diesel engines except that the 3.0L system does not have a DPF fuel injector in the exhaust system for regeneration. The 3.0L system uses post injection from the main injectors during a DPF regeneration event instead of a DPF fuel injector.


Diesel Exhaust Fluid


The Diesel Exhaust Fluid (DEF) tank is installed on the frame on the left side of the vehicle. It includes a Level & Temperature Sensor, a drain plug and a tamper-resistant filler insert to prevent filling with fluids other than DEF. A visual DEF level gauge is helpful when filling the tank. (Fig. 5) The internal pickup includes the Coolant Heating Tube and Gauge Sending Unit. The pickup is serviced as a complete assembly.


F05 LCF DEF tank 7

Fig. 5


The DEF gauge (Fig. 6) on the instrument cluster indicates the quantity of DEF remaining in the DEF tank. When only one green bar is showing, the DEF tank is almost empty and should be refilled soon. If the vehicle is driven too long with only one bar, the green will change to amber and additional warnings and indicators will display. Vehicle speed will be severely limited when the DEF tank is empty.


F06 LCF DEF gauge 8

Fig. 6


The DEF indicator lamp on the instrument cluster will illuminate if there is a malfunction of the SCR system, the DEF level is too low or empty, of the DEF tank is refilled with any fluid other than DEF.




Vehicle Pigtail Connector


The Low Cab Forward trucks use the vehicle pigtail connector as the communication gateway (similar to the Diagnostic Link Connector, or DLC, on other GM vehicles) from which a Vehicle Health Report can be downloaded. The connector is accessible after removing the relay fuse cover in the center of the lower dash panel. Behind the panel, the connector is located in the lower right corner of the opening. It has a green identifying mark under the clear plastic cover.


Connect the RS232 Cable (Fig. 7, #2), which is an essential tool, to the vehicle pigtail connector (Fig. 7, #1) and to a laptop USB port with GDS 2 installed. Once connected, the Vehicle Health Report can be downloaded. The ignition must be on with the engine off throughout the download procedure. Two blue lights on the RS232 cable will flash while the download is in process.


F07 LCF pigtail connector 9

Fig. 7




There are currently 90 service tools that a dealership may need for this program. However, each dealership’s actual tool cost and/or need is dependent on their current tool inventory. In addition, nine of the service tools are available through the Loan Tool Program.


For additional information on the Low Cab Forward medium-duty trucks, refer to Bulletin #16-NA-337.


– Thanks to Bob Briedis


Damaged Shipping Container Restraining Belts

Many service replacement engines, transmissions and transfer cases are delivered to dealerships in shipping containers that use a ratchet-style restraining belt. The belt is used to securely hold the component in place inside the shipping container. (Fig. 8)


F08 shipping case

Fig. 8


The shipping container also is used to return the core unit of the replaced component. Recently, some cores have been returned with the restraining belts cut, leaving the core unsecured in the container.


TIP: When the new component is received in the dealership, release the belt in the shipping container using the ratchet mechanism. (Fig. 9) Do not cut the webbing of the belt.


F09 shipping ratchet belt

Fig. 9


Secure the Core Unit


Once the core unit to be returned has been placed into the shipping container, use the belt to secure the core. Tighten the belt enough to prevent movement in the bottom of the container.


Core units returned to the Warranty Parts Center (WPC) or the Core Center that have had the belts cut (Figs. 10, 11), leaving the component unsecured, may be subject to a warranty claim debit.


F10 shipping belt 1

Fig. 10


F11 shipping belt 2

Fig. 11


Refer to the instructions now being included in the shipping containers for proper operation of the ratchet-style restraining belt and complete shipping instructions.


Containers with Damaged Belts


If a service replacement engine, transmission or transfer case assembly with a cut or damaged belt is received in your dealership, contact Matt Stedman by email at or by phone at 586-419-9370 with the details of your order. All belts in the containers are being inspected prior to shipping.


– Thanks to Mark Gordon

Two Fobs Needed for RKE Transmitter Quick Learn on 2017 Models

For 2017 model year vehicles, excluding Acadia Limited, Enclave, Traverse, Express and Savana models, adding a new Remote Keyless Entry (RKE) transmitter, or key fob, using the quick learn procedure requires that two previously learned transmitters be present. (Fig. 12)


F12 2 fobs

Fig. 12


TIP: If only one transmitter is present, the procedure will not complete and a Remote Learn Pending message will display on the vehicle’s Driver Information Center. The new transmitter will not be learned and cannot be reprogrammed.


If only one transmitter is available, use SPS to add a new transmitter to the vehicle instead of the quick learn procedure.


On 2016 and earlier model years, only one previously learned transmitter is needed to be present to perform the quick learn procedure.


Programming Additional Transmitters


The Adding Transmitters, also referred to as Adding Keys, programming does not erase any keys. The programming simply adds a key into the next available slot. Up to eight transmitters can be learned to a single vehicle. If a new transmitter is being learned to replace a damaged, inoperative, or stolen transmitter, follow the Replacing Transmitters procedure to ensure that an old transmitter cannot be used.


Before performing the quick learn procedure to add a transmitter, verify all mechanical keys operate correctly.


The quick learn procedure typically requires the two previously learned transmitters to be placed in the vehicle cupholder in the center console (if equipped) or to turn the ignition on/off with both transmitters.


To initiate programming, each new transmitter is placed in the transmitter pocket (Fig. 13), which is located in the center console storage compartment (if equipped) or the new key/transmitter is placed in the ignition switch. The ignition is turned to the ON position (do not crank the engine). The vehicle theft light on the instrument cluster will turn off or the Driver Information Center will indicate the key/transmitter is learned.


Be sure to keep other transmitters at least 12 inches (30 cm) away from the ignition switch or transmitter pocket while learning.


F13 transmitter pocket

(Fig. 13)


Refer to #PIC6208 for additional information on the quick learn procedure for 2017 models.


Refer to the appropriate Service Information for complete details on RKE transmitter programming for each specific GM model.


– Thanks to Chris Crumb

Shift to Park Message with Five DTCs Set

2017 Malibu and Volt models. These models are equipped with the 5ET50 automatic transmission (RPOs MKV, MKE), which is an electronically-controlled, continuously-variable electric transmission (or drive unit) on hybrid models. (Fig. 14)


2017 Chevrolet Volt Voltec Drive Unit

Fig. 14


The following DTCs may be set:

P1AEE – Drive Motor 1 Control Module Hybrid/EV Battery System Voltage High Voltage

P1AEF– Drive Motor 2 Control Module Hybrid/EV Battery System Voltage High Voltage

P1AF0 – Drive Motor 1 Control Module Hybrid/EV Battery Voltage System Isolation Lost

P1AF2 – Drive Motor 2 Control Module Hybrid/EV Battery Voltage System Isolation Lost

P1E22 – Auxiliary Transmission Fluid Pump Control Module Hybrid/EV Battery Voltage System Isolation Lost


If only two or three of these DTCs are set, follow the appropriate Service Information diagnostic procedures. The cause may not be any internal components of the transmission.


If all five DTCs are set, there is an internal fault with the transmission and the transmission requires replacement. Do not attempt any internal repairs.


Refer to #PIP5321 for more information on the Volt 5ET50 (RPO MKV) transmission restriction program.


Refer to #PIP5390 for more information on the Malibu 5ET50 (RPO MKE) transmission restriction program.


Refer to this TechLink article for additional information on loss of isolation on high voltage systems.


– Thanks to John Riker

Service Know-How

The latest service topics from Brand Quality and Engineering are reviewed, including an update on the new 2017 Service Training Standards and how to perform a software update on the AFIT diagnostic tool. (Fig. 15)


F15 EI image 2

(Fig. 15)


To view Emerging Issues seminars:

• Log in to • Select Resources > Video on Demand > GM STC > Search Videos; or • Select Catalog to search for the course number, and then select View > Take or Continue Course

New Essential Tool GE-52200 Propulsion System Lift

The new GE-52200 Propulsion System Lift table (Fig. 1) is designed for the removal/installation of electrical vehicle batteries as well as engines, transmission, transaxles, fuel tanks, suspensions, cradles and chassis system components.


Chevrolet Bolt EV dealerships are the first recipients of the GE-52200 lift table. All other U.S./Canadian dealerships will begin receiving the table as an essential tool in late 2017 or early 2018.


F01 lift table 1

Fig. 1


The air/hydraulic lift table has a capacity of 1,760 lbs. (798 kg) and a maximum lift height of 70 inches (178 cm), which can be actuated with a foot control pump. (Fig. 2) Connecting to shop air requires a quick connect fitting (not included).


F02 lift table air

Fig. 2


It features a 60/40 split table top that allows powertrains to be separated while mounted to the table. (Fig. 3) The length of the table is adjusted by releasing the pins and sliding the table in or out. It automatically locks into position at several set points.


F03 lift table top

Fig. 3

The lift handle can be quickly attached to either side of the lift using quick-release pins. The lift table also is easy to move around the service bay. The 360-degree swivel casters have integrated foot butterfly locks and detent locks for directional movement control. (Fig. 4)


F04 lift table caster

Fig. 4


This Lift Table Promotional PDF provides additional information.


Bolt EV High-Voltage Battery Removal


During removal of the high-voltage battery pack (also referred to as the drive motor battery), vehicle weight will be redistributed. Secure the vehicle to the lift/hoist arms with straps so that the vehicle does not become unstable on the hoist. Also support the vehicle with jack stands at the opposite end from which any major components are removed.


There is a Center of Gravity (C.G.) mark on the drive motor battery tray to locate the lift table. (Fig. 5) The high-voltage battery pack mass is approximately 1,000 lbs. (450 kg).


F05 Bolt EV battery CG

Fig. 5


Remove all connectors and mounting fasteners (Fig. 6) from the drive motor battery before lowering the lift table. Secure the battery to the lift table with straps.


F06 Bolt EV bolts

Fig. 6


– Thanks to Chuck Berecz

Sort It Out — New Service Information Table Sorting Features

The GM Service Information has implemented a number of new features recently designed to make it easier and more efficient to quickly access the information needed in the service bay every day.


Table Sorting


One of these new features is the ability to now sort the tables of the Master Electrical Component List. The list provides the component code, name, option code, location of the component on the vehicle, a link to the locator view, and links to related connector end views.


Users can now sort any column by selecting the directional arrows at the top of each column heading. (Fig. 7)


F07 MEC list 1

Fig. 7


The table also can be filtered by inputting a search word in the box at the top of the column. For example, under the Name column, enter “transfer” to filter the results with transfer in the name. (Fig. 8)


F08 MEC list 2

Fig. 8


Labor Time Guide Search


Another new feature of the Service Information is the Labor Time Guide search function. Use the search function to find a labor time by the labor operation number. Select “Titles” in the search box and then enter the labor operation number. The corresponding labor time guide will be displayed. (Fig. 9)


F09 LTG sort

Fig. 9


– Thanks to Lisa Scott

Inductive Charging Test Tool Adapter

A new Test Tool Adapter (EL-51755-UPD) has recently been shipped to all GM dealerships for use with the EL-51755 Inductive Charging Test Tool. The charging test tool is used to verify the charging system operation in a GM vehicle. The adapter (Fig. 10), approximately the size and shape of a typical mobile phone, makes it easier to place the test tool in the correct location on both charging pockets and charging pads. Proper positioning is critical to ensure the charging coils of the charging surface and the mobile device, or test tool, line up correctly to allow charging.


F10 inductive charging test tool adapter 4

Fig. 10


Adapter Installation


To install the adapter on the test tool, thread the strap on the tool, from the back of the adapter, through the rectangular slot near the top of the adapter. Next, align the tool with the back of the adapter and press it into place. (Fig. 11) The adapter should remain attached to the tester at all times.


F11 inductive charging test tool adapter 1

Fig. 11


Wireless Charging Compatibility


The first step in diagnosing a wireless charging condition is to validate that the customer’s device is compatible with the vehicle charging system. The latest version of #PIC6049 lists compatible phone models and if a phone has built-in wireless charging capability or an available wireless charging case. It also provides the maximum dimensions for devices that can be charged. Large devices may not be compatible.


When testing the charging system, or charging a device, be sure to remove all objects from the charging pocket or pad. Coins, keys, cards, or other items trapped between the phone and the charging surface can prevent charging and may become very hot.


Refer to this recent TechLink article for examples of different charging systems and tips on charging a mobile phone. [LINK recent TechLink article TO]


Testing using the EL-51755 Test Tool


The EL-51755 Inductive Charging Test Tool should be reasonably centered in the pocket or pad to align with the vehicle sensor. The adapter allows the tool to simply be inserted into the pocket. (Fig. 12) It will fit snugly and will align properly once fully inserted. On a charging pad, place the tester flush with the rear of the pad. (Fig. 13)


F12 inductive charging test tool adapter 3

Fig. 12


F13 inductive charging test tool adapter 2

Fig. 13


For both the pad and pocket, ensure that the flat side (non-LED side) of the tool aligns against the flat charging surface. There is no need to remove the rubber sleeve from the pocket or pad for testing.


To verify the operation of the charging system, simply place the tool in the pocket or on the pad with the vehicle ignition on. If the tool’s wireless charging indicator illuminates after a few seconds, the charging system is operating properly and any charging concern may be caused by an incompatible or defective mobile device. If the charging indicator is off, continue diagnosis using the appropriate Service Information.


To complete the test successfully, the procedure may need to be repeated five times. Between each attempt, remove the tool and wait two seconds


For additional information on the tool, check out the January Emerging Issues Seminar 10217.01V available through the GM Center of Learning at In Canada, view the December 2016 TAC Talk video; Infotainment segment.


– Thanks to Chuck Berecz and Bob Wittmann

Unwanted Brake Apply in Reverse without Park Assist Activation

Some 2016-2017 CT6 and 2017 XT5 models may have an unwanted brake apply condition while in Reverse when there is no object behind the vehicle or around the vehicle. This condition may occur most often when the vehicle is cold in the morning (overnight cold soak) or has been sitting outside for several hours in colder temperatures.


The performance of the rear Short Range Radar Sensor may be degraded at cold ambient temperatures below 50°F (10°C), which may result in unintended brake activation while the vehicle is backing up.


The rear Short Range Radar Sensor, located behind the rear fascia (Fig. 14, XT5 shown), is designed to detect objects up to approximately 98 feet (30 meters). The rear Short Range Radar Sensor communicates with the Active Safety Control Module via serial data on the object detection bus as part of the backing warning system and the rear automatic braking system.


F14 XT5 sensor R

Fig. 14


Once the rear Short Range Radar Sensor warms up to temperatures above 50°F (10°C), the condition is not present and may not be duplicated in the dealership.


Do not replace any parts or attempt any repairs for this condition. GM Engineering is determining a root cause. To address this condition at this time, use remote start to start the vehicle before driving, which will allow the rear Short Range Radar Sensor to warm up, or turn off the Park Assist feature (Fig. 15, CT6 shown) when backing up after a cold start.


F15 CT6 park assist

Fig. 15


– Thanks to Katul Patel

Harsh Shifting on the 8L90 Automatic Transmission

There may be several harsh shifting conditions on some 2015-2016 Silverado, Sierra, Yukon and Escalade models equipped with the 5.3L engine (RPO L83) or 6.2L engine (RPO L86) and the 8L90 automatic transmission (RPOs M5U, M5X). The shift conditions may include:

• Harsh 1-2 upshift (except for the first 1-2 upshift of the day) • Harsh 3-1 downshift when de-accelerating to a stop • Harsh downshift under heavy throttle apply • Active Fuel Management (AFM) V4 to V8 transition harshness (6.2L engine only) • Coast-down downshifts (6.2L engine only)


There is new Engine Control Module (ECM) and/or Transmission Control Module (TCM) software that is available to improve these conditions. Use the Service Programming System (SPS) and follow the on-screen instructions to complete the programming. If both controller options are listed in SPS, select K20/K71 Transmission Control Module.


Do not install this calibration if the vehicle is not exhibiting these conditions. It is not intended to be installed on these vehicles for any other conditions.


TIP: Installation of the new TCM software will require that the Transmission Service Fast Learn (SFL) procedure be performed using GDS 2 or SPS through the TIS2Web application. The transmission may exhibit poor shift quality until the clutch values are learned. Performing the SFL will reset and relearn all the shift adapts.


After the programming of the TCM (Fig. 16) is complete, evaluate the shift quality of the transmission. Refer to Bulletin #16-NA-019 for more information about the transmission adaptive functions, how to learn the clutches and improve shift quality.


TIP: Due to the installation of the new TCM software, Bulletin #14-07-30-001 should not be used on 2015 model year vehicles. It will not allow for proper clutch learning.



Fig. 16


Transmission Shift Adapts


The 8-Speed automatic transmission (Fig. 17) uses a line pressure and volume control system during upshifts to compensate for new transmission build variation as well as the normal wear of transmission components. The variation from new and normal wear of the apply components within the transmission over time can cause shift time (the time required to apply a clutch) to be longer or shorter than desired.


2015 Hydra-Matic 8L90 (M5U) Eight Speed RWD Automatic Transaxle

Fig. 17


In order to compensate for these changes, the TCM adjusts the pressure commands to the various pressure control (PC) solenoids to maintain the originally calibrated shift timing. Referred to as “adaptive learning,” this adjusting process ensures a consistent shift feel and increases transmission durability. Transmission adapts can be reset and relearned using the Transmission Service Fast Learn procedure that is completed in the service stall.


When the Service Fast Learn is complete, perform a test drive and note any soft or harsh shifts. Within GDS 2, a Transmission Service Fast Learn Data page is available to aid in performing adaptive learning by showing throttle percentage, engine speed, transmission fluid temperature, and gear command.


For additional information, refer to this TechLink article on reprogramming the 8L90 transmission or the TechLink article providing an overview of the new 8L90 transmission.


– Thanks to Matt Bunting and Dave Peacy

Topping Off Diesel Exhaust Fluid

Diesel Exhaust Fluid (DEF) is required to maintain normal vehicle operation and emissions compliance on 2010-2017 Express and Savana; 2011-2017 Silverado and Sierra 2500-3500 HD; 2014-2015, 2017 Cruze; and 2016-2017 Colorado and Canyon models equipped with a diesel engine (RPOs L5P, LML, LGH, LUZ, LWN, LH7). DEF usage will vary depending on driving style, trailer towing, loaded vehicle weight, weather, idle time and PTO use. It’s recommended to refill the DEF tank at the first opportunity after a low warning message in order to avoid any vehicle speed limitations.


Below OK Level


The DEF level indicator is displayed on the Driver Information Center (DIC) along with a series of messages regarding the amount of DEF that is available. Typically, when the DIC shows the DEF to be at any level below OK (Fig. 1), at least 2.5 gallons (9.5 L) can be added to the DEF tank (this has not yet been verified on the 2017 Cruze). The amount needed to top off the tank will vary.


F01 DEF level

Fig. 1


DEF has a shelf life of two years. However, this can be reduced if the fluid is exposed to direct sunlight or temperatures above 86°F (30°C) for sustained periods. All DEF packaging is labeled with a production date.


Filling the Tank


The DEF fill location, identified by the blue fill cap, is different on several models:

• 2010-2017 Express, Savana; 2016-2017 Colorado, Canyon; 2017 Cruze – Behind the fuel fill door • 2014-2015 Cruze – Under the trunk floor • 2011-2017 Silverado, Sierra – Underhood (Fig. 2)


F02 DEF fill

Fig. 2


TIP: After filling the DEF tank – unless the DEF tank was empty and the Exhaust Fluid Empty message was displayed – there may be a short delay (several miles/km) before the increased level of fluid is detected and the DIC is updated.


Typically, DEF warning messages on the DIC begin once the estimated range falls below 1,000 miles (1,609 km). When the DIC displays 1,000 miles or less, a 2.5 gallon (9.5 L)  container of DEF can be added to the tank. DEF fluid range will vary based on environmental conditions and vehicle use. To eliminate the DEF warnings, once the range drops below 300 miles (482 km), the DEF tank should be refilled.


If the vehicle speed has been limited and DEF has been added, it may take up to 30 seconds after starting the engine with the vehicle stopped for the Exhaust Fluid Empty Refill Now message to clear. If the vehicle is driven prior to the DIC message clearing, the vehicle speed will still be limited. If the DIC message clears while driving, the speed limitation will be removed gradually.


On diesel models equipped with RPOs L5P, LH7 or LWN, a Service Emission System message may display on the DIC after filling the DEF tank with the ignition on. This message may appear when using a mobile fill cart with an automatic nozzle or filling up at a commercial truck service station with DEF dispensing equipment. DTC P206B (Reductant Quality Sensor Circuit Performance) may be set. Some DEF filling equipment use pumps that create a high level of temporary aeration of the DEF fluid, which temporarily affects the operation of the in-tank DEF quality sensor. After the aeration quickly dissipates, the sensor will return to normal operation. However, if the ignition is on, the DIC message may be displayed. The ignition should be kept on until the Service Emission System message clears.


DEF in Cold Weather


DEF freezes when exposed to temperatures below 12°F (-11°C). In cold conditions, it is normal for DEF to freeze. The tank and delivery lines are heated to thaw frozen DEF.


When filling the tank in cold conditions, the vehicle may not recognize the new fluid level until the tank thaws. In certain cold conditions, it is possible to find some frozen DEF in the DEF fill pipe opening. When driving in extremely cold areas, it is recommended to fill the DEF tank prior to cold temperature exposure.


– Thanks to Larry Yaw


Updated February 24, 2017

AutoStop Active during Low-Speed Maneuvers

The 2016-2017 ATS and CTS feature the Auto Engine Stop/Start (AutoStop) system (RPO KL9), which turns off the engine when the brakes are applied and the vehicle is at a complete stop (depending on operating conditions). When the brake pedal is released or the accelerator pedal is applied, the engine will restart.


When AutoStop is active, it may interfere with low-speed maneuvers and while parking the vehicle. This is a normal characteristic of the system and no repairs should be made.


If drivers find the operation of the AutoStop feature to be objectionable is certain situations, it can be disabled using the AutoStop button. The system should be disabled before attempting the low-speed maneuvers.


On CTS models, the AutoStop button is located next to the infotainment screen. (Fig. 3) On ATS models, the button is located on the center console by the shift lever. (Fig. 4) When the system is disabled, the button indicator will not be illuminated and the AutoStop symbol on the instrument cluster will change from green to white with a slash through it.


F03 autostop button CTS

Fig. 3


F04 autostop button ATS

Fig. 4


– Thanks to Rob Ritz

Multi-Media Interface Tester Tool Update

The Multi-Media Interface Tester (EL-50334-20) (Fig. 5), which can be used to verify auxiliary, USB and Bluetooth connectivity between a device and a GM infotainment system, has recently received several updates that are available through a new software download.


F05 MIT image 2

Fig. 5


When diagnosing an infotainment system condition, the Multi-Media Interface Tester (MIT) offers the ability to deliver pass or fail testing on several systems, which provides a known good device for accurate and reliable diagnosis. The MIT will confirm Bluetooth pairing with the vehicle and can place a test call to confirm the Bluetooth system is working properly. The MIT outputs four distinct audio files to test the Bluetooth, Auxiliary/Line-In, and USB functions of the audio system. The operation of each test function is confirmed by a confirmation message played back through the vehicle’s audio system.


Updated Software


Features of the updated software include:

• New support of Secure Simple Phone pairing, which is the only way to pair a phone with the Info 3.0 Infotainment System that will be first available on the 2017 CTS. Secure Simple Pairing is a more seamless handshake between the mobile phone and the Infotainment system using a 6 digit PIN instead of the previously used 4 digit PIN. • FAT32 USB compatibility, which many of the Next Generation Infotainment (NGI) and new Infotainment Systems use to communicate to the external USB drive. The previous MIT software was FAT16, which may have caused issues with the newer systems. These issues are eliminated with the new FAT32 protocol.


The software update is available at (U.S.) (Fig. 6) or (Canada).


To update the MIT:

1.     Log in to the website.

2.     Select the latest MIT update.

3.     Click the Download MIT Update/Utility link.

4.     Select Run to run the download file.

5.     Follow the on-screen instructions to update the MIT.

6.     When the software update has completed, the MIT is updated.


F06 software website

Fig. 6


– Thanks to Dan Hrodey

Avoid Turbocharger Damage during Service Work

When performing underhood service work on the 2016 Cascada, use care to avoid damage to any turbocharger components on the 1.6L engine (RPO LWC).


Recently, turbochargers returned under warranty have had damage to the wastegate actuator solenoid vacuum port fittings (Fig. 7, A) and bypass valve port fittings. (Fig. 7, B) Service parts are available for the bypass valve, wastegate solenoid and wastegate actuator in kits.


Do not replace the turbocharger assembly for damage to these components.


F07 turbo clip R

Fig. 7


TIP: In addition to the 1.6L engine, this information applies to all four cylinder engines equipped with a turbocharger.


– Thanks to Javier Hinojos

Truck and Snow Plow Headlamp Flicker

When equipped with snow plow equipment (Fig. 8), the headlamps of the truck or snow plow may flicker or be inoperative on some 2014 Silverado 1500 and Sierra 1500 models and 2015-2017 Silverado and Sierra models. This condition may occur on either the left or right lamp assembly. DTCs B2575 (Headlamps Control Circuit) and B2699 (Right Headlamp Control Circuit) may be set.


F08 snow plow

Fig. 8


Some snow plow manufacturers offer a headlamp changeover module for switching between the truck’s headlamps and the snow plow’s headlamps. Depending on the type of headlamps on the truck and how they are controlled, the headlamp changeover module may not operate correctly with the truck’s headlamp system, which can cause either or both of the truck and/or snow plow headlamps to flicker during changeover.


This condition is not related to the truck’s headlamp system. Contact the snow plow manufacturer for information on the headlamp changeover system.


Additional information can be found on the GM Upfitter website at Under the Technical Bulletin tab, click “Show all bulletins” and select UI Bulletin 116 Snow Plow Lamp Activation.


GM Upfitter Website


The GM Upfitter Integration website — — offers a variety of valuable information and assistance for technicians and other personnel. (Fig. 9)


F09 upfitter website image

Fig. 9


Here, you’ll find body builder manuals; technical bulletins covering design changes, upfitter modifications and other issues; generic Incomplete Vehicle Documents (IVD) for Chevrolet Express, Silverado, Colorado and GMC Savana, Sierra, Canyon and others, and best practice manuals with engineering recommendations and guidelines for Special Vehicle Manufacturers. There is also a section on FAQs as well as links to some helpful sites, such as GM Fleet, Chevrolet Commercial Vehicles, GM Mobility and more.


– Thanks to Jim Will

Service Know-How

10217.01V – Emerging Issues

January 13, 2017


The latest service topics from Brand Quality and Engineering are reviewed, including highlights of the Rear Seat Reminder feature (Fig. 10) and how to update the software in several diagnostic tools.


F10 EI image

Fig. 10


To view Emerging Issues seminars:

• Log in to • Select Resources > Video on Demand > GM STC > Search Videos; or • Select Catalog to search for the course number, and then select View > Take or Continue Course

The Bolt EV Charges Ahead in the Electric Vehicle Market

As the first long-range, affordable electric vehicle (EV) from an established automaker, the new Chevrolet Bolt EV (Fig. 1) is charged with bringing electrical propulsion to a whole new range of consumers. With a fully-charged high voltage battery, the Bolt EV offers an EPA-estimated 238 miles (383 km) of electric range, which is five times the amount needed for the average daily commute of 40 miles (64 km).


F01 Bolt EV profile

Fig. 1


The Bolt EV is a front-wheel-drive, five passenger, four door hatchback available in LT and Premier trim levels. It features a sleek, low profile thanks to an innovative high voltage battery cell arrangement that provides a flat floor while maximizing interior space.


The centrally located battery pack provides an optimal center of gravity for excellent ride and handling. At approximately 3,569 pounds (1,619 kg), the Bolt EV is light for a car with such a large battery pack. It comes standard with 240 volt and 120 volt charging capability.


100% Electric Propulsion


The propulsion of the Bolt EV is achieved by a fully automatic, variable-speed, electric drive transmission. The permanent-magnet synchronous AC electric motor provides 200 horsepower and 266 lb.-ft. of torque. The electric motor, drawing power from the 60-kWh battery pack, is capable of launching the car from 0 to 60 mph (97 km/h) in approximately 6.5 seconds, according to GM testing.


The 60-kWh nickel-lithium-ion high voltage battery assembly, which is removed and installed from underneath the vehicle, is protected by a lightweight steel frame integrated into the body structure. (Fig. 2)


2017 Chevrolet Bolt EV

Fig. 2


Vehicle Range


The Bolt EV displays three range numbers on the digital instrument cluster: a maximum, minimum, and a prominent best estimate based on the individual’s driving style and accessory usage, including climate control settings, headlights and audio use along with ambient conditions.


The range varies based on several factors:

• Driving techniques such as speed and acceleration. The exponential effects of aerodynamic drag means that the faster the Bolt EV is driven, the faster the battery will drain. • The terrain the vehicle encounters, such as hilly areas or long steep grades in mountainous areas. • Ambient temperature. • Use of the HVAC system for heating and air conditioning in order to maintain cabin temperature and passenger comfort. • Use of the audio system.


Charging Corridors


The United States Department of Transportation has announced it is establishing 48 charging corridors or routes covering nearly 25,000 miles in 35 states. Along these routes, drivers will be able to expect a charging station every 50 miles. The new charging stations, which will serve as the basis for a national network, will be identified by signs similar to those used to alert drivers to gas stations, lodging and food.


Natural Resources Canada (NRCan) also has announced an initiative to support the installation of a number of vehicle fast-charging units along key transportation corridors within Canada. British Columbia, Ontario and Québec have announced plans to setup local charging networks within their respective provinces.


One-Pedal Driving Operation


One-pedal driving uses the highest available level of regenerative braking, which captures otherwise lost energy from deceleration and sends it back to the high voltage battery pack, to allow the driver to slow the vehicle by simply lifting off the accelerator pedal. Regenerative brakes does not eliminate the need to use the brake pedal altogether.


The amount of regenerative braking can be initiated by the driver using the Regen on Demand paddle on the back of the steering wheel. Shifting the transmission to the L position further increases the level of regenerative braking.


EV Cooling System


The Bolt EV is equipped with three fully-independent cooling systems that are designed to cool the power electronic components, cool and heat the high voltage battery, and provide heat to the passenger compartment. The battery pack has an integrated, liquid-cooling tray circulating 1.82 gallons (6.9 liters) of DEXCOOL™ coolant to keep the high voltage battery cool as well as a separate heating element for warm-ups in colder climates.


Located within the battery pack is a Battery Energy Control Module that monitors the temperature, current and voltage of the 96 battery cell groups. Diagnostics and system status are communicated from the Battery Energy Control Module to the Hybrid/EV Powertrain Control Module 2.


A/C System


The high voltage electric A/C compressor is a self-contained high voltage inverter, electric motor, and direct coupled compressor. The electric A/C compressor has the ability to run and provide cooling performance while the vehicle is not running. The electronic climate control module and the Vehicle Integration Control Module (VICM) will command the electric A/C compressor to a speed necessary to maintain a desired cooling level rather than cycle the electric A/C compressor on and off.


The electric A/C Compressor uses Polyolester (POE) refrigerant oil. Use only approved GM POE oil no more than two hours after removal from its sealed moisture proof packaging.


Color Digital Displays


The cabin of the Bolt EV features a 10.2-inch (259 mm) color touchscreen mounted in the center of the instrument panel and a 8.0-inch (203 mm) color digital gauge cluster. (Fig. 3) Both displays provide operating information and system settings, such as the battery charge level, range estimation, charge settings and climate controls.


2017 Chevrolet Bolt EV

Fig. 3


Windshield Wipers


The windshield wiper motor module controls the up and down wiper arm movement using a reversing motor and an internal position sensor. The sensor keeps track of the gear wheel position. When the controller determines that the wiper arms are at a position to reverse direction, it reverses the motor supply voltage.


There is a wiper motor for each arm. The left and right motors allow the system to operate each wiper blade independently.


When replacing or adjusting a windshield wiper arm, position the wiper arms correctly by installing the wiper arm at the lower blackout of the windshield and the wiper arm blades to the correct marks. (Fig. 4)


F04 BoltEV wipers

Fig. 4


Pedestrian Safety Signal


The vehicle is equipped with an automatic sound generator. The sound is automatically generated at speeds of less than 14 mph (23 km/h) to indicate the vehicle’s presence to pedestrians.


An available Front Pedestrian Braking system also is offered that can detect when approaching a pedestrian too quickly and provide a boost to braking or automatically brake the vehicle. The system can detect and alert to pedestrians in a forward gear at speeds between 5 mph (8 km/h) and 50 mph (80 km/h).


Special Tools


The following new tools were released for the 2017 Bolt EV:

Screen Shot 2017-01-12 at 11.26.11 AMScreen Shot 2017-01-12 at 11.26.22 AM


For more information about the new 2017 Bolt EV, refer to Bulletin #16-NA-393.


– Thanks to Sherman Dixon and Chuck Wieseckel



Bolt EV Propulsion System

The propulsion of the Bolt EV (Fig. 5) is achieved by an electric drive transmission that transfers the energy from the high voltage battery pack to the front drive wheels.


2017 Chevrolet Bolt EV

Fig. 5


Drive Motor Battery System


The high voltage battery is designed to last for the life of the car and is covered by an 8-year/100,000-mile (160,000 km) warranty. The high voltage battery assembly is removed and installed from underneath the vehicle. The battery pack is protected by a lightweight steel frame integrated into the body structure.


The Battery Energy Control Module, a current sensor, and the high voltage contactors are located within the hybrid/EV battery assembly. The Hybrid/EV Powertrain Control Module 2 is mounted within the passenger compartment, beneath the right front seat.


Battery Construction


The hybrid/EV high voltage battery weighs approximately 946 lbs. (429 kg) and contains 288 individual nickel-lithium-ion cells. (Fig. 6) Three cells are welded together in parallel in a cell group. There are a total of 96 cell groups in the hybrid/EV battery assembly that are electrically connected in series. Each individual cell group is rated at 3.5 volts, for a nominal system voltage of 344 volts of direct current (DC).


2017 Chevrolet Bolt EV battery system

Fig. 6


Because the high voltage battery was engineered specifically for the Bolt’s arduous duty cycle, the 288 prismatic cells have greater nickel content and, therefore, will run slightly warmer than those in the Chevrolet Volt or the Chevrolet Spark EV.


The hybrid/EV battery pack contains a total of 6 battery temperature sensors mounted to certain battery cell modules. The hybrid/EV battery pack also contains a coolant inlet temperature sensor.


Located within the high voltage hybrid/EV battery pack is the K16 Battery Energy Control Module which monitors the temperature, current and voltage of the 96 battery cell groups. The voltage sense lines are attached to each individual cell group.


Diagnostics and system status are communicated from the Battery Energy Control Module to the K114B Hybrid/EV Powertrain Control Module 2


The battery pack will be serviceable by certified GM dealerships when necessary. Some of the battery pack’s accessory components are located under the hood for easier access.


TIP: The hybrid/EV high voltage battery will be on TAC Restriction and Exchange during the vehicle launch period. Batteries will be distributed by an Electronic Service Center.


System Components


The Hybrid/EV high voltage battery assembly consists of the following components. (Fig. 7)


F07 Bolt EV components

Fig. 7

1. K10 Coolant Heater Control Module. Service Part Name: Heater Coolant Heater.

2. T6 Power Inverter Module. Service Part Name: Drive Motor Power Inverter Module.

3. Hybrid/EV Battery Assembly. Service Part Name: High Voltage Battery.

4. S15 Manual Service Disconnect. Service Part Name: Drive Motor Battery High Voltage Manual Disconnect Lever.

5. E54 Hybrid/EV Battery Pack Coolant Heater. Service Part Name: High Voltage Battery Heater.

6. G1 A/C Compressor. Service Part Name: Air Conditioning and Drive Motor Battery Cooling Compressor.

7. T18 Battery Charger. Service Part Name: Drive Motor Battery Charger.

8. K1 14V Power Module. Service Part Name: Accessory DC Power Control Module.

9. T24 Battery Charger-DC. Service Part Name: High Voltage Battery Disconnect Control Module Assembly.


Electric Drive Transmission


The electronically-controlled, fully automatic transmission consists primarily of a 150kW drive motor, a differential/offset gear set, a high voltage electric auxiliary transmission fluid pump and housing, and two axles. (Fig. 8)


2017 Chevrolet Bolt EV drive unit

Fig. 8


The differential/offset gear set provides the fixed forward and reverse ratio. Changing speed and torque is fully automatic and is accomplished through the use of a drive motor generator power inverter control module located under the hood. The drive motor generator power inverter control module receives and monitors various electronic sensor inputs and uses this information to vary the torque output to the drive axles based on throttle position.


The lubrication system uses an electric auxiliary fluid pump motor assembly located outside of the transmission for lubrication of rotating components. The transmission fluid pump operates under low pressure and will only run when out of Park or Neutral and vehicle speed is detected.


Gear position is selected using the Electronic Precision Shift (EPS) system, which is also used on the new Buick LaCrosse and Cadillac XT5. The shift-by-wire systems sends electronic signals to the drive unit to select the drive mode. The selected gear position illuminates in red on top of the shift lever. After shifting, the lever returns to the center position.


TIP: The transmission will not stay in Neutral for an extended period. It will automatically shift into Park.


– Thanks to Sherman Dixon and Chuck Wieseckel



Charging the Bolt EV

There are three different charging levels that can be used to charge the Bolt EV. (Fig. 9)


F09 Bolt EV plugged in

Fig. 9


• AC Level 1 is plugging in to a typical 120V/12 amp home outlet using the provided portable charge cord. It will charge the vehicle at a rate of 4 EV miles per hour of charging using the 12 amp setting. The 8 amp charge limit should be used until a qualified electrician inspects the electrical circuitry of the home, or if the electrical circuit or outlet capacity being used is not known. • AC Level 2 is plugging in to a 240V/32 amp outlet using an available charging station, which will charge the vehicle at a rate of 25 EV miles per hour of charging. • DC Fast Charging stations are available in many public areas. (Fig. 10) Using the SAE Combo connector will charge the vehicle to approximately 80 percent of capacity in about 60 minutes. The DC Fast Charging port is optional on U.S. models and standard on Canadian models.


2017 Chevrolet Bolt EV

Fig. 10


Charging Status Indicator


The charging status indicator on top of the instrument panel quickly identifies if the vehicle is charging. (Fig. 11)


F11 charge status indicator R

Fig. 11


Single Tone and Flashing Indicator – The vehicle is plugged in and the battery is charging. The number of flashes indicate the current percentage of battery charge:

1 Flash: 0–25% Charged

2 Flashes: 25–50% Charged

3 Flashes: 50–75% Charged

4 Flashes: 75–99% Charged

Solid Light: 100% Charged


Slow (long pulse) Flashing Green Indicator with Double Tone – The vehicle is plugged in; battery charging is delayed.


Solid Green Indicator – The vehicle is plugged in and the battery is fully charged.


Solid Yellow Indicator – The vehicle is plugged in; not charging.


No Light – The vehicle is not plugged in or there is an issue with the charger or outlet.


The charging system may run fans and pumps that result in sounds from the vehicle when it is turned off. Additional unexpected clicking sounds may be caused by the electrical devices used while charging.


Charge Mode and Charge Limit


The Charging screens on the infotainment display show the Charge Mode and Charge Limit status. The vehicle has three programmable charge modes: Immediately, Delayed based on departure time, and Delayed based on electric rates and departure time. (Fig. 12) There are two available Charge Limits: the 8 amp setting and 12 amp setting.


F12 Charge mode

Fig. 12


Location-Based Charging


The Bolt EV’s charge settings can be programmed for when the vehicle is at home or away. Using the GPS signal in the car, it can identify when it is home and will activate the charge settings according to the customized preset charging times. Charging can even be delayed until utility rates are at their lowest off-peak prices, which is usually at night. When away from the home location, the Bolt EV will charge immediately when plugged in.


To set the home location, go to the Energy Home screen and select Energy Settings > Location-Based Charging. Next, select On and Update Home Location. Add the required information to set the current vehicle location as the Home location.


Charge Cord Strap Installation


During PDI, a Velcro strap included in the trunk bag should be installed to the charge cord stowage compartment. The strap is used to retain the portable charge cord when not in use.


Insert the strap through the two holes on either side of the charge cord stowage compartment. (Fig. 13) Use the strap to secure the portable charge cord. (Fig. 14)


F13 charge cord straps

Fig. 13


F14 charged cord stowed

Fig. 14


– Thanks to Sherman Dixon and Chuck Wieseckel

Bolt EV Reprogramming

Several precautions should be taken before reprogramming various control modules on the 2017 Bolt EV.


TIP: Verify the battery voltage is more than 12.6 volts but less than 15.5 volts before proceeding with reprogramming. The 12V battery must be fully charged before reprogramming. Use the Midtronics® PSC 550 Battery Maintainer (EL-49642) to maintain a battery voltage of 12.6-15.5 volts.


Body Control Module


When reprogramming the K9 Body Control Module (BCM), begin with the vehicle in the Power Off mode. The Service Programming System (SPS) will power mode the vehicle.


Engine Control Module


Before reprogramming the K20 Engine Control Module (ECM), it’s necessary to disconnect the X2 connector (Fig. 15, #1) from the ECM (Fig. 15, #2), located underhood. If the X2 connector is not disconnected, it will cause the ECM to reset during the reprogramming procedure and the re-flash will fail.


Also turn off the ignition before disconnecting or connecting any connectors to the ECM in order to prevent internal ECM damage.


F15 BoltEV ECM

Fig. 15


Hybrid Powertrain Control Module


Before programming the K114A Hybrid Powertrain Control Module, verify the 12V battery is fully charged and the hood is closed. Programming with the hood open could result in a no-start condition. If a no-start condition occurs, close the hood and refer to the Service Information regarding “Clear Secured High Voltage DTCs.” Normal operation should return after the hood is closed.


The Hybrid Powertrain Control Module also should be programmed in the Power Off mode with the brake pedal applied. The brake pedal apply keeps the BCM awake throughout the programming event.


Hybrid Powertrain Control Module 2


Do not program the K114B Hybrid Powertrain Control Module 2 with the drive motor battery (high voltage battery) charger cable connected to the vehicle. Charging while programming may result in damage to the High Voltage Battery Disconnect Relays.


Power Line Communication Module


The K190 Power Line Communication Module communicates with a DC Fast Charging station. Do not program the Power Line Communication Module with the drive motor battery (high voltage battery) charger cable connected to the vehicle. Charging the drive motor battery while programming may result in damage to the DC charging contactors.


– Thanks to Chuck Wieseckel and Steve Falko

Engineering Information Bulletins and Part Restrictions

05 Restrictions 01062017 image 105 Restrictions 01062017 image 205 Restrictions 01062017 image 305 Restrictions 01062017 image 405 Restrictions 01062017 image 505 Restrictions 01062017 image 6

New 2017 Colorado and Canyon Action Center Now Available

A new GM Technical Assistance Center (TAC) Action Center has been established for the 2017 Colorado and Canyon (Fig. 1) equipped with the new high feature 3.6L V6 engine (RPO LGZ) and 8L45 8-speed transmission (RPO M5T). The Action Center is available to provide dealerships with additional support for the introduction of this new powertrain.



Fig. 1


Dealerships are asked to call the Action Center regarding any powertrain performance or operation conditions. The Action Center is connected directly to TAC, Engineering, and the assembly plant so that any product concerns can be resolved quickly.


GM encourages dealerships to report all product conditions, not just those requiring technical assistance. Digital photos and audio/video files for various conditions also may be requested.


Compared to the previous 3.6L V6 engine, RPO LGZ features improved variable valve timing and direct injection along with Active Fuel Management, which disables two cylinders under light throttle applications.


Featuring four gearsets and five clutches, the 8L45 transmission fits in the same space as the previous 6-speed transmission while offering added efficiency.


– Thanks to Charles Hensley

Battery Learn Procedure Update for Stop/Start System

A new Power on Reset feature has been added to 2017 models equipped with Engine Stop/Start. As a result, the battery learn procedure is no longer required after a battery disconnect on 2017 Encore, Envision, LaCrosse, Regal, Verano, ATS, CT6, CTS, XT5, Cruse, Impala, Malibu, Trax, and Acadia (VIN N) models with Engine Stop/Start (RPO KL9). The Battery Sensor Module 3-hour learn procedure has been removed from the Service Information for these models. 2017 models with Stop/Start have an AUTO STOP position on the tachometer. (Fig. 2)



Fig. 2


With the Power on Reset feature, the following parameters were added to the Diagnostic Aids section of the Service Information – Stop/Start Malfunction:

• Battery Sensor Module Battery State Information = Available/Not Available • Battery Sensor Module Reset Occurred – Using Estimated State of Charge = Yes/No


GDS 2 will display these parameters under Engine Control Module > Stop/Start System Data.


Power on Reset is active when the parameters read:

• Battery Sensor Module Battery State Information = Not Available (Not Learned), and • Battery Sensor Module Reset Occurred – Using Estimated State of Charge = Yes (Estimated).

The Stop/Start system is enabled when Power on Reset is active.


The vehicle will continued to use an estimated state of charge until it sits for three hours. It will then start using the actual state of charge value from the Battery Sensor Module. (Fig. 3, 2017 LaCrosse shown) The Engine Stop/Start feature will function normally before and after the learn occurs.



Fig. 3


– Thanks to Rob Ritz

Electrical Conditions Resulting from Damaged Wiring Harness

A number of electrical conditions, including the instrument cluster gauges drop out, the radio and HVAC displays are blank, no crank/no start, and several Driver Information Center messages displayed, may be present on some 2013-2014 Malibu models. The air bag fuse may be blown and several communication DTCs may be set. These conditions may be caused by the wiring harness rubbing against the seat frame or a short to ground in the 5060 circuit.


To duplicate these conditions, the passenger seat must be occupied. If the conditions are found, inspect the passenger-side seat wiring harness (Fig. 4, #1) for possible damage and improper routing through the seat frame. (Fig. 4, #2)



Fig. 4


If the harness (Fig. 5, #1) is damaged or improperly routed, remove the passenger seat and re-route the harness away from the frame. Disconnect the electrical connector (Fig. 5, #2) if necessary.



Fig. 5


Also inspect the harness for any chafing or exposed wire. Repair the harness as needed and wrap the harness using a double layer of Woven Polyester Electrical Tape. (Fig. 6, #1) Secure the harness to the seat wiring harness with Woven Polyester Electrical Tape. (Fig. 6, #2)



Fig. 6


– Thanks to Ron Caponey

  • [+]2017
  • [+]2016
  • [+]2015
  • [+]2014