January 2005

Volume 7, No.01

A Monthly Publication for GM Dealership Service Professionals

Wireless Headphones and Remote Controls

have three different 15140532 (Visteon) Headphone Package (DVD RSE)
remote controls and
they are not compatible PART NUMBER QUANTITY ITEM
(Malibu Maxx, Trail- 15762534 2 Headphone Assembly
Blazer, and Uplander). (1 Channel Wireless)
However, the head-
22698894 1 Control Assembly – Video
phones are compatible Player Remote
with all GM DVD sys-
tems except the mini- 15073730 1 Pack Battery Package –
vans, which require a 2- Headphone 4 - AAA
channel wireless head- 15072561 1 Pack Battery Package – Video
phone. If the 2-channel T/Player Remote Control
headphones are used 2 - AA
in the wrong vehicle, 22727857 1 Instruction – Video Disc
channel 2 (RSA) will not Player Operation
be audible, but channel 15140533 1 Instruction – Video Disc
1 (DVD) will be audible. Player
Malibu Maxx headphone kit (System 1a)
To help keep these
components straight, wireless headphones. The other GM vehi-
Because the wireless headphones and here’s some information about the systems cles have RSA systems which use wired
remote controls for GM DVD RSE (Rear in use. headphones (which are not provided to the
Seat Entertainment) and RSA (Rear Seat
customer).
Audio) systems are loose items, it’s possi- System 1a – DVD RSE
ble for them to become separated from the The following headphone kit (p/n
The following headphone kit (p/n
vehicle they’re intended for, before the vehi- 10396845) is released for the 2005-07
15140532) is released for the 2005-07
cle is delivered to the customer. In many Malibu Maxx with RSA option (UK6).
Malibu Maxx only. The remote control will
cases, these items are not interchangeable not work with any other GM vehicles. continued on page 3
among vehicles. If the wrong components
are provided to the customer, dissatisfaction System 1b – RSA without DVD RSE
will result. TIP: The Malibu Maxx is the only current
For example, a Chevrolet dealership will GM vehicle that offers an RSA system with

Contents
Techline News Wireless Headphones and Remote Controls . . . . .1
End of Support for Windows 98,
Millennium, NT 4.0 . . . . . . . . . . . . . . . . . . . . . . .1
End of Support for Windows 98, Millennium and NT 4.0 DRL Disable Qualifications and Process . . . . . . . .2
Attention: All Service Department Personnel Programming a Replacement Module . . . . . . . . . .2
Top Tier Gasoline Update . . . . . . . . . . . . . . . . . . .2
Beginning January 1, 2005, GM operating systems and PC hardware, go MP3 Radio Software Upgrade . . . . . . . . . . . . . . .3
Service and Parts Operations will dis- to http://service.gm.com/techlineinfo/ Synthetic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . .3
continue ALL support for Windows 98 techlinepc.html. Review this document Pulse Wiper Operation . . . . . . . . . . . . . . . . . . . .3
(Second Edition), Millennium and NT before making a business grade Techline Tips for Servicing .64 Terminals . . . . . . . . . . . . . .4
4.0. An announcement concerning PC purchase. Fuel Filter Replacement . . . . . . . . . . . . . . . . . . .5
the end of support was distributed to Questions regarding the information Vibe, Wave and Aveo Fuel Filter . . . . . . . . . . . . . .5
dealers on October 31, 2003 under above can be directed to your local Cadillac STS Keyless Access System . . . . . . . . . .6
administrative message VMG20030999 Techline Consultant (TC) or the Techline Fuel Line Quick Connectors, revisited . . . . . . . . . .6
(In Canada, dealer communication dated Customer Support Center (TCSC). TC Know-How Videos on GM Training Website . . . . . .7
November 27, 2003). During this year, contact information can be found on Creaking or Popping Front Doors . . . . . . . . . . . . .7
the Techline Customer Support Center http://service.gm.com/techlineinfo/ Roof Water Leak . . . . . . . . . . . . . . . . . . . . . . . .7
(TCSC) provided “one call limited sup- techlinepc.html. TCSC can be reached at Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . .7
port” for the operating systems men- 1.888.337.1010, prompt 3. From Canada, Brake Moan . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
tioned above. The one call limited sup- 1.800.828.6860 (English) or Fix It Right the First Time . . . . . . . . . . . . . . . . . .8
port will be discontinued on January 1. 1.800.503.3222 (French). Know How Broadcasts for February . . . . . . . . . . .8
For additional detail regarding supported - Thanks to Shawn Sullivan
continued on page 2 Service and Parts Operations

1
Techline News — from page 1

Daytime Running Lights cle, and stating the reason. The letter
Disable Qualifications must indicate which features are to be
disabled. For example, both AHL and GM TechLink is a monthly magazine
and Process DRL disabled*. The letter must for all GM retail technicians and
In GM Service Operations’ continu- include the specific VIN(s) of the vehi- service consultants providing timely
ous effort to provide the fastest cus- cles which will be disabled and this information to help increase knowl-
tomer support possible, the following statement: “The DRL/Auto Headlamp edge about GM products and
process is in effect for those select system will be made fully opera- improve the performance of the
governmental agencies that request tional prior to disposal/sale of the service department.
and qualify for disabling Daytime vehicles listed above.” In addition,
the letter needs to be signed by a Manager, Product Readiness:
Running Lights (DRL).
representative of the official agency. R. M. (Bob) Savo
TIP: In Canada, disabling of DRLs is
The letter must be kept in the ser- GM Service and Parts Operations
/bob.savo@GM.com
not permitted by Transport Canada. vice history file at the dealership, and a
1. Only the following governmental copy sent to TCSC before the disable
agencies qualify for this disable procedures will be released. In most Publisher & Editor:
request: City/State Government, cases, the vehicles will require a soft- Mark Stesney
Police/Sheriff Departments, FBI, CIA, ware change that requires a special VCI GM Service and Parts Operations
DEA, and emergency vehicles if gov- override. /Mark.Stesney@GM.com
ernment owned. * TCSC will make every attempt to
2. All requests are to be made through honor these requests. In some cases, Technical Editor:
the Techline Customer Support it is not possible to disable a feature.
Jim Horner
/Jim.Horner@SandyCorp.com
Center (TCSC) at 1.888.337.1010. Example: AHL disable is not possible on
1999 and later S/T Trucks. Contact TCSC
3. The dealership will be required to
to see if disabling the desired feature 1-248-816-3641
obtain a letter on official agency let-
is possible on your specific vehicle.
terhead requesting the disable, stat- Production Manager:
ing that the agency owns the vehi- – Thanks to Abby Slagor
Marie Meredith
Desktop Publishing:
Important Information Greg Szpaichler, MediaWurks
/greg@mediawurks.com
der of the standard procedure to install

3
About Programming a the data into the replacement module.
TIP: The default choice is
Replacement Module Reprogram, and if you use it, you will
FAX number:
1-248-649-5465
*
You must begin by using your Tech 2 receive an ERROR message. If after
to obtain information from the vehicle. following this procedure, you still get Write to:
Always follow proper procedures and the ERROR message, contact Techline
precautions. Customer Support Center. TechLink
After selecting Service Programming PO Box 500

:
Systems in TIS, you have a choice Troy, MI 48007-0500
between: GM TechLink on the Web:
– Reprogram
– Replace and Reprogram http://service.gm.com
General Motors service tips are
intended for use by professional tech-
nicians, not a "do-it-yourselfer." They
are written to inform those techni-
cians of conditions that may occur on
some vehicles, or to provide informa-
tion that could assist in the proper
The Reprogram choice is used only service of a vehicle. Properly trained
to reprogram a module that will con- technicians have the equipment, tools,
tinue to be used in the vehicle safety instructions and know-how to
do a job properly and safely. If a con-
(installing the latest calibrations, for dition is described, do not assume
instance). that the bulletin applies to your vehi-
You now MUST select Replace and - Thanks to Abby Slagor and cle or that your vehicle will have that
Reprogram. Then follow the remain- Craig Jones condition. See a General Motors deal-
er servicing your brand of General
Motors vehicle for information on
whether your vehicle may benefit from
the information.
Inclusion in this publication is not nec-
Top Tier Gasoline Update essarily an endorsement of the indi-
vidual or the company.
Shell and Entec Stations (Montgomery, AL) have been added to the Top Tier list.
Copyright© 2004 General Motors Corporation
These brands have been added to the running list on the TechLink website.
All rights reserved.
- Thanks to Jay Dankovich

2
Wireless Headphones and Remote Controls — from page 1

10396845 (Visteon) Headphone Package (DVD RSA) 15072230 (Panasonic) Headphone Package (DVD RSE) TIP: The remote control will work only
in these GM vehicles. Channel 2 of the
PART NUMBER QUANTITY ITEM PART NUMBER QUANTITY ITEM
wireless headphones will work only in these
15762534 2 Headphone Assembly 01999421 2 Headphone Assembly vehicles (Channel allows you to listen to
(1 Channel Wireless) (1 Channel Wireless) DVD and Channel 2 allows you to listen to
15073730 1 Pack Battery Package – 01999355 1 Control Assembly – Video RSA).
Headphone 4 - AAA Player Remote There are two DVD systems available:
System 2 – DVD RSE 15085989 1 Pack Battery Package – – A base system U56 comes with
Headphone 4 - AAA a remote control kit only
The following headphone kit (p/n
15072230) is released for the 2005-06: 15085988 1 Pack Battery Package – Video (no headphones available).
– Buick Rendezvous and Rainer T/Player Remote Control – An uplevel system U42 comes
2 - AA with a remote control kit and a
– Cadillac Escalade, EXT, ESV, SRX
headphone kit.
– Chevrolet Avalanche, Silverado Crew System 3 – DVD RSE
Cab, Suburban, Tahoe, TrailBlazer The following two kits (p/n 15136091 and TIP: Headphone kit TX3 can be added to
– GMC Envoy, Sierra Crew Cab, Yukon, 15136092) are released for the 2005-07: either system.
Denali, XL, XL Denali – Buick Terraza TIP: Batteries are not included.
– Pontiac Aztek – Chevrolet Uplander
– Saturn Vue. – Pontiac Montana SV6 15136091 (Hosiden) Headphones Only Package
– Saturn Relay. (DVD RSE)
PART NUMBER QUANTITY ITEM

15185391 2 Headphone Assembly

(Dual Channel Wireless)

15136092 (Hosiden) Headphones Only Package

(DVD RSE)
PART NUMBER QUANTITY ITEM

15190411 1 Control Assembly - Video

Player Remote

TIP: If a kit is misplaced or was not

shipped with the vehicle, follow established
procedures for misplaced/missing compo-
nents. The service part numbers for the kits
System 2 headphone kit
are the same as the OEM part numbers.
- Thanks to Jeri Betts, Dwayne Hall and
TIP: The remote control will work only in Typical minivan DVD RSE headphone kit Matthew Marchiori
these GM Vehicles.

MP3 Radio Software Upgrade Synthetic Oil

This information applies to 2005 Buick Rainier, Chevrolet The following 2005 engines have synthetic
Colorado, SSR, TrailBlazer, and TrailBlazer EXT and GMC Canyon, engine oil installed at the engine plant.
Envoy, and Envoy XL vehicles with MP3 (RPO US8) Radio CD 2.0L LSJ 4.6L LH2
Player. A software anomaly within the radio has been found. 3.6L LY7 Cadillac only 6.0L LS2
Some owners may comment that when playing a CD the TIP: When servicing these engines, use oil that meets the
radio displays the last track number for about 5 seconds, but GM4718M specification, as outlined in the Owners’ Manual.
there is no audio. The display changes to "READING" for about Not all synthetic oils will meet this GM standard.
15 seconds. Then it may play the CD or eject the CD with a
"CHECK CD" message. - Thanks to Robert Stockwell
TIP: Each dealership will receive the "2005 US8 MP3 Radio
Software Upgrade" CD through the Dealer World Delivery
(DWD Box) process the week of November 29th, 2004. Pulse Wiper Operation
TIP: This disc does not This information applies to 2005 Chevrolet Cobalt (Pontiac Pursuit
apply to Chevrolet in Canada) and Pontiac G6
Equinox. On these vehicles, there are three wiper modes: Pulse, Low and High.
Install the software up- In the Pulse mode, the wiper timing will fluctuate with the vehicle
grade CD into MP3 radio. speed. If the vehicle speed is below 50 mph (80 km/h), the wipers
Allow the software files to will take up to 3 seconds between wipes.
transfer completely. This TIP: In certain weather situations, if vehicle speed is below 50
should take 1-2 minutes. mph (80 km/h), the customer may find it necessary to switch the
This installation should correct the condition noted above. wipers to the Low mode.
- Thanks to Doug Daugherty - Thanks to Steve Oakley

3
Tips for Servicing .64 Terminals
If you’ve been following the various sto- an update to this probe. The latest version minals back into place. If you do disas-
ries in TechLink about electrical terminals has a blue wire and a more robust silver semble, you’ll have to remove all the
over the past few years, you know that terminal probe. Use the probe carefully to terminals and wires from the connector.
numerous new types of terminal and con- avoid damage to the terminal. Reassemble the connector and then rein-
nector systems have been introduced (Tech- TIP: The earlier probe has a white wire stall the terminals and wires into the
Link, Sept. 2002, June 2003, Feb. 2004). and a gold terminal probe. connector.
One type of terminal, the .64, is offered Watch for an expanded explanation of
by several suppliers, and there are slight this in an upcoming issue of TechLink.
differences between them. The informa- Molex – A new Molex connection sys-
tion here is intended to clarify these dif- tem is used on some ECMs. It uses a
ferences. square type .64 terminal number 33467-
TIP: The 0003 or 33467-0005 depending on wire
supplier of a size. Both are found in Delphi tray 23.
system can New J-35616-64A Old J-35616-64A
often be test probe test probe
determined
by locating TIP: The J-35616-64A and J-35616-65
and identifying test probes are correctly sized to substi-
the manufac- tute for both the round and square male
turer’s symbol terminals.
on the Terminal and Connector
connector. Systems
There are The following paragraphs describe vari-
two different ous terminal and connector systems from
types or styles of male terminals that will several suppliers. One type to be aware Molex
mate with the .64 female terminal. These of is the hybrid type, which uses both .64
are the .80 mm round style (Delphi and terminals and other sizes of terminals in There is only one style of this connec-
Bosch), and the .64 mm square style the same connector. tor in use so far. The TPA surrounds the
(AMP/Tyco, Bosch, JST, Molex and Yazaki). It is assumed in all of the following that terminal area, and the color matches the
The GM corporate intent is to use only the connector wire cover, if used, has ECM header color. Lift the TPA up slightly
the Yazaki .64 terminal in the future. So been removed. to the preset position. Use the gray
you will see more of this terminal in the All of the following terminals are in the J-38125-213 terminal release tool. Insert it
future. A new crimp tool is being devel- J-38125 Terminal Repair Kit and in the tray into the small hole in the TPA next to the
oped that will crimp the Yazaki square and indicated. terminal you wish to remove. Once the
Bosch round .64 terminals. new terminal has been pushed back into
Delphi – Many different Delphi connec-
tor shapes and styles are in use. All position, press the TPA back into place.
Delphi .64 connection systems use termi- Sumitomo – A new Sumitomo connec-
nal 15359541, which is found in the tion system is used on some ABS mod-
Delphi tray 4. ules. It uses a square type .64 terminal
8100-3455 in the Sumitomo tray 22.

A Stationary contact of female terminal

B .80 mm round terminal
C .64 mm square terminal

Terminal contact geometry

TIP: It is not recommended to attempt

to distinguish between the .64 terminal Sumitomo Hybrid
and the 100 terminal just by looking. The
best way to be sure is to use the .64 There is only one style in use so far, but
test probe (J-35616-64A) initially. If the Delphi Hybrid others will follow. At first glance, this con-
J-35616-64A probe seems obviously too nection system looks like it uses a termi-
small, move to the 100 sized probe. These connectors require the careful nal larger than a .64. The white TPA sur-
If a male 100 terminal (or test probe, or removal of the comb style TPA (Terminal rounds the terminal area. Lift it to remove.
anything incorrect) is inserted into a .64 Position Assurance). They will break very This is difficult and feels like it is going to
female, the .64 terminal may split. This easily if extreme care is not used. Use break. Use the green 12094429 terminal
destroys the terminal’s retention capabili- the 15381651-2 terminal release tool release tool. Insert it next to the terminal
ty. When that damaged .64 terminal is pushed into the small hole between two you wish to remove and lift the plastic
reconnected, tension is too low to ensure terminal cavities. tang that holds the terminal. Once the new
proper contact and continuity. TIP: Do not disassemble the Delphi terminal has been pushed back into posi-
connector body any more than removing tion, press the white TPA back into place.
Test Probe
the TPA and in some cases, a nosepiece Tyco – Several Tyco systems are in use.
All of these connection systems use the One of them is used on the Medium
J-35616-64A test probe. There has been that covers the small terminal release
holes. It is very difficult to get all the ter- continued on page 5

4
Tips for Servicing .64 Terminals — from page 4

Duty Truck ABS module. It uses a square Once the new terminal has been pushed plastic tang that holds the terminal. Once
type .64 terminal 962885-5 in the Yazaki back into position, press the red TPA back the new terminal has been pushed back
tray 15. into place. into position, press the white TPA back
into place.
A Tyco connection system is used on
the Transmission Control Modules (TCM)
of the Cadillac SRX, STS and CTS.

Tyco
Tyco Hybrid
A Tyco connection system is used on
There is only one style of this connec- sunroof modules and other small mod-
tor in use so far. Use a small screwdriver ules. It uses a square type .64 terminal
to move the two tabs of the blue TPA out 1123343-2 in the Lear tray 7.
slightly to the preset position. Use the
green 12094429 terminal release tool. Tyco Hybrid
Insert it into the small rectangular hole
next to the terminal you wish to remove, This connection system also uses a
moving the plastic tang that holds the ter- square type .64 terminal 2-1411578-2 in
minal. Once the new terminal has been the Yazaki tray 15. Remove the strain
pushed back into position, move the blue relief (the cover on top of the connector).
TPA back into place. Then, depress the lock tab on the side of
Another Tyco connection system is Tyco the connector and move one of two
used on SD modules. It uses a square white TPAs aside to the pre-staged posi-
type .64 terminal. The service terminals in There are several styles of this connec- tion. Insert the green 12094429 terminal
this connector are the terminated leads tor in use with different terminals. You release tool into the small rectangular hole
1393365-2-SIR in the new SIR tray. There must carefully lift the white TPA on the next to the terminal you wish to remove.
is only one style in use so far. Lift and top of the connector. Do not remove. This Move the plastic tang that holds the ter-
remove the red TPA that surrounds the TPA actually surrounds the terminal, so minal. Once the new terminal has been
terminal area. Use the black 15315247 you will damage it if you try to get it com- pushed back into position, move the white
terminal release tool. Insert it next to the pletely out. Use the green J-38125-24 ter- TPA back into place. This connector is
terminal you wish to remove and lift the minal release tool. Insert it next to the shown in the Wiring Systems section of SI.
plastic tang that holds the terminal. terminal you wish to remove and lift the - Thanks to John Roberts

Fuel Filter Replacement Vehicles with Non-Serviceable Fuel Filters

Chevrolet
Some customers have commented The vehicle owner’s manual outlines 2003 -05 Corvette
that they have been advised to replace the periodic maintenance service
their vehicle’s fuel filter periodically. 2004-05 Malibu and MAXX, Silverado*,
required, under the Maintenance 1 and Tahoe**, Suburban, Avalanche
On many vehicles, the fuel filter is non- Maintenance 2 guidelines. Routine fuel
2005 Equinox, Cobalt, Aveo, Trailblazer
serviceable (see table). The filter is an filter replacement does not appear on and EXT, SSR
integral part of the fuel pump module and either of these schedules. GMC
fuel pressure regulator assembly. The fil- In the future, due to the increased reg-
ter can be serviced only by replacement 2004-05 Sierra*, Yukon** and XL
ulation of evaporative emissions, fuel sys-
of the fuel module assembly. This tems utilizing a non-serviceable filter will
2005 Envoy, XL and XUV
process requires the removal of the fuel Pontiac
become more common as new models
tank (one to two hours of labor, depend-
are introduced. 2003-05 Vibe
ing on the model), plus several hundred
dollars in unnecessary parts. - Thanks to David MacGillis 2005 G6, Pursuit ***, Wave***
Buick
2005 Rainier
Pontiac Vibe and Wave, and Cadillac
Chevrolet Aveo Fuel Filter 2004-05 XLR, Escalade, EXT and ESV
On the Pontiac Vibe, Pontiac Wave (Canada) and Chevrolet Aveo, the fuel filter Hummer
is serviced as part of the fuel pump module, as described in the preceding para- 2006 H3
graphs. Saturn
TIP: However, on these vehicles, if fuel pump module/fuel filter replacement 2002-05 VUE
is required, it is not necessary to remove the fuel tank. There is an access panel
beneath the rear seat. When it's removed, the fuel pump module can be removed. 2005 ION
Refer to SI for details. * 2004 V8 only (4.3L uses conventional external filter)
** 2004 RPO L59 uses conventional external filter
*** Canada Only

5
Cadillac STS Keyless Access System
NO FOBS DETECTED. Briefly it says the TIP: If the keyless access transmitter is
no-start condition may be caused by equip- not detected inside the vehicle while try-
ment the driver has plugged into the acces- ing to turn the ignition off, the NO FOB
sory power outlet in the center console. OFF OR RUN message displays.
These could include cell phones and charg- The vehicle may be near a strong radio
ers, two-way radios, power inverters, etc. antenna signal, causing the keyless
TIP: PDA devices and remote garage access system to be jammed. The vehicle
and gate openers may also interfere with will remain in ACCESSORY until OFF or
the keyless access transmitter. The owner START has been pressed or 10 minutes
is advised not to carry the keyless access has expired.
The STS uses the same basic keyless transmitter in the same pocket or bag as
system as the XLR (TechLink, Feb. 2004) IMPORTANT: If the ignition is turned off
these devices. and the keyless access transmitter cannot
and Corvette (TechLink, Aug. 2004). The
TIP: Locations such as airports, auto- be detected, the vehicle will not restart.
STS operates at the same frequencies as
matic toll booths, and some gas stations The keyless access transmitter needs to
the XLR and Corvette (315 MHz for
have fields which may interfere with the be detected inside of the vehicle in order
domestic, 433 MHz for Europe).
keyless access transmitter. for the vehicle to start.
The STS may be susceptible to RF
TIP: The owner is advised to move the Multiple Fobs Present
(radio frequency) interference or EMI
transmitter to different locations within
(electromagnetic interference). Under certain circumstances, several
the vehicle. If this
This includes not being able to enter the does not help, place people carrying valid keyless access
vehicle or start the engine. The driver can the transmitter in the transmitters (fobs) may approach the vehi-
use the mechanical key or call OnStar to center console cle at the same time. This will not affect
open the door. But once inside, pressing transmitter pocket door opening.
the Start button may not start the engine. with the buttons After the driver’s door is opened, the
Unnecessary Parts Replacement facing forward and driver preferences for the lowest driver
then press the number will be recalled. Depending on
These operating conditions are not a which person’s fob is programmed as
fault of the BCM, PCM, or other control START button.
If the vehicle Driver 1, the actual driver’s preferences
modules or components. Replacing them may not be activated.
will not remedy the condition. To help you battery is
understand what normal operation is, sufficiently Battery Replacement
refer to the following paragraphs. charged, The vehicle will display a message when
this action the fob battery is low. Until this occurs,
Tips from the STS Owner’s Manual will ALWAYS there are no effects on the system.
TIP: The STS owner’s manual explains enable the
the no-start condition under the heading of vehicle to start. - Thanks to Tobin Davis

Fuel Line Quick Connectors, revisited

This updates information originally in tor off. Do not attempt to remove the nector, the friction between the barb and
the February 2004 issue of TechLink. retainer while the connector is still the retainer will make it difficult to release
Three styles of fuel line quick connects attached to the mating line. the quick connect feature.
are now in use. A. Raymond – To release the quick con- TIP: Attempting to remove the retainer
The TI Group© Global Quick Connector nect, put finger pressure on both release on the TI Group connector with the line
is used on C/K trucks, S/T trucks, Malibu buttons simultaneously. Push first toward inserted will result in retainer breakage.
Sedan, Cadillac XLR, Chevrolet Cobalt, the barb on the steel or plastic line, then TIP: If a quick connect does not release
Saturn ION, Chevrolet HHR, and the pull the quick connector off. with hand pressure, thoroughly clean it and
2004.5 and 2005 blow out grit and dirt with compressed air.
Chevrolet Corvette.
The Legris© (pronounced Repair
“la-gree”) QC is used on TI Group – If the retainer is broken, it is
Aztek, Rendezvous, not necessary to replace the entire fuel line
Venture, Montana and and attached component to repair it. Three
Silhouette and on the sizes of replacement retainers are available
internal line connection Legris –
to the sender module Replacement 5/16-inch 21992748
on the Malibu Sedan. Depress with hand pressure only
parts are not 3/8-inch 22717568
The A. Raymond© (pro- available for this
nounced “a ramone”) QC is used on the Do not use sharp or pointed objects to 5/8-inch 21992746
retainer.
Malibu Maxx and on the Pontiac G6. put pressure on the connector retainer/
release buttons. Using a tool may fracture A. Raymond –
Release the retainer, making it less effective at Replacement
TI Group and Legris – To release the keeping the connector assembled. It may parts are not
quick connect, push on the retainer using be easier to release the connector if it is available for
hand pressure only. first pushed toward the barb on the mat- this retainer.
ing line. If one attempts to release the - Thanks to Replacement retainer
Push first toward the barb on the steel available for
or plastic line, then pull the quick connec- quick connect while pulling on the con- David MacGillis TI Group type only

6
You Can Review Know-How Videos on GM Training Website
As you know, new Emerging Issues You can use this new web feature as an – Log on to the www.gmtraining.com
and New Model Features programs are on-demand tool to recall information right website. You will need your personal
broadcast monthly on the GM satellite at the time you need it. ID and password.
network, according to the schedule pub- – In the menu, click on TECHAssist.
lished on page 8 of each issue of Keyword Search
TechLink. Repeat programs are also An important feature of the website is – Click the Service Know-How logo.
broadcast throughout the month. the keyword search capability. With it, you – On the video search page, you can
Because there’s a lot of information in can pinpoint a specific video segment. launch a video program, or you can
these broadcasts, GM is now providing You can even search keywords in the search for specific content using the
you a way to review the material on the sound track. search parameters in the left window.
www.gmtraining.com website. At a des- Logon Procedure TIP: You can also launch a video from
ignated time after Emerging Issues and the online course catalog.
Here’s how to begin using these
New Model Features broadcasts, the
videos will be available on the website. videos. - Thanks to Steve Sternicki

TACTips

Creaking or Popping Front Doors Headlamp Switch

This information applies to 2004-05 Do not replace either check link or the After replacing the headlamp switch
Chevrolet and GMC Full Size 2500HD and door hinge to address this issue. on a 2003 full size truck or utility you
3500 trucks with the letter F in VIN posi- Remove the bolt, clean the threads and may notice the following changes.
tion 11, designating the Flint asembly reapply Loctite® 242, GM p/n 12345382 1. The green and amber LED (light
plant. At this plant, between March and (GM p/n 10953489 in Canada). Install the emitting diode) indicators are miss-
September, 2004, the torque guns used bolt and torque to 25 Nm (18 lb ft) ing from the face of the switch.
to attach the door check link to the pillar 2. Trouble code B0951 will be set
were set to a low torque level. - Thanks to Jim Will
in the BCM after a replacement
switch is installed.
This is a normal condition. No repairs
Roof Water Leak Release the hose from the mastic patch should be attempted.
on the pillar and from the clip. Gently pull A running change was implemented
On some 2005 Chevrolet Equinoxes the hose downward so the edge of the
with RPO CF5 (sunroof) or CE1 (OnStar), starting with the 2004 model year and the
rubber portion can be seated against the new replacement switch doesn’t have the
water may leak from the headliner or map
bottom side of the clip when reinstalled. “auto” and “disable” LED indicators.
light. Here’s what to look for.
On vehicles with OnStar, be sure the Confirm The BCM will store a trouble code
antenna is firmly secured. Run water over that the hose B0951 when a replacement switch is
the antenna to confirm it is not leaking. is pointing installed on a 2003 vehicle. This is due
Next, check the condition of the sunroof downward at to the deletion of the LEDs and will not
drain hoses. Open the sunroof and release the joint to change the operation of the DRLs and
the dual lock fasteners along the front the sunroof. headlamps.
edge. Carefully pull the front edge of the Then, secure- - Thanks to Paul Radzwilowicz
ly seat the Incorrect
headliner down to visually inspect the sun-
roof drain hoses at the left and right front hose into the
corners of the sunroof module. mastic patch.
Pour a small
Brake Moan
The sunroof drain hoses must be point-
ing downward from the connection to the amount of Owners of some 2003-05 Chevrolet,
sunroof module to ensure water can water into the GMC and Cadillac 1500 Utilities may
quickly drain away and to prevent stress sunroof mod- comment on a brake moan, hoot or fog
on the connecting joint. A stressed joint ule area adja- horn type noise from the brakes.
will slowly drip water onto the headliner cent to the Correct This concern may be somewhat diffi-
and this water can get to the map light. drain connec- cult to duplicate and happens only after
tion. If leakage is evident, the hose may the vehicle is driven for a distance of 20-
still be pointing slightly upward. 30 miles (32-48 km). The noise is most
audible when the brakes are applied
TIP: It may be necessary to remove the between 20-40 mph (32-64 kph) and
visor to give you more freedom of move- the brake pedal is lightly released.
ment to rotate or position the drain hose TIP: The noise may sound like it is
downward. from the front, when in fact it is from
If the leak cannot be stopped, remove the rear brakes.
the drain hose and seal it to the module. Inspect the rear brake rotor surfaces
Incorrectly positioned drain hose TIP: It may be necessary to remove the for scoring or a grooving pattern which
B pillar upper trim to get enough move- may look like a vinyl phonograph
To correct the condition, remove the A ment in the headliner to access the drain record.
pillar trim on the affected side. hose for sealing. To correct this concern, machine the
TIP: It is not necessary to remove the - Thanks to Ron Erman rear rotors and block sand the pads.
headliner. - Thanks to Jim Will
7
 Car Issues – Fix It Right the First Time
Reference
Model Year(s) Vehicle Line(s) / Condition Do This Don’t Do This Information / Bulletin

1997-2005 Buick Century, Regal – Broken Armrest Replace lid latch only. Don’t replace console armrest lid (Regal) or 03-08-49-018A
Lid Latch front seat center storage armrest (Century)
when only latch is needed to repair condition.
2004-2005 Grand Prix – Outside Rearview Mirrors Replace mirror glass or motor, Don’t replace complete mirror 04-08-64-009
whichever is defective. assembly.
2004 Grand Prix – Steering, Suspension or Re-torque right steering gear mount. Don’t replace steering gear or cradle. 03-02-32-048
Cradle Click Noise
2000-2003 Century, Regal, Lumina, Impala, Monte Replace upper intake manifold Don’t replace upper intake manifold 03-06-01-016
Carlo, Grand Prix, Intrigue with 3.8L L36 gasket only. assembly for coolant leak condition.
Engine – Coolant Leak
2001-2004 Aztek (01-04), Rendezvous (FWD, 02-04), Follow procedure in bulletin using Don’t replace converter assembly for 03-06-05-003
Venture/Montana/Silhouette (01-04) – clamp P/N on down pipe to correct rattle/buzz noise without completing
Pop and/or Rattle in Exhaust Down Pipe rattle/buzz noise. instructions in bulletin.
2000-2004 All Cars with 4T40/4T45E and 4T65E – Light Check transmission 20-way connector for Don’t replace transmission, TCC 02-07-30-022B
On/Various Transmission Codes Stores secure connection (disconnect and reconnect). PWM, VSS, PCS or valve body.
2000-2004 Seville – Heated Seat Inoperative Replace only needed heating element. Don’t replace entire seat cover if 01-08-50-002C
heated seat element is inoperative.
2000-2004 Cavalier/Sunfire/Alero/Grand Am – Retime module or replace only motor Don’t replace entire sunroof module 03-08-67-009A
Inoperative Sunroof Module for inoperative complaints. assembly.
2003-2004 Cavalier/Sunfire – Air Conditioning Inspect for ground out conditions that Don’t replace A/C compressor for 03-01-38-012
Compressor Noisy can cause A/C compressor noise excessive noise complaint without
complaints. inspecting for ground outs.
1999-2004 All Cars and Trucks – Brake Warranty, Issue One: Refinish brake rotor. Issue One: Don’t replace the brake rotors. 00-05-22-002D
Service and Procedures Issue Two: Measure for LRO Issue Two: Don’t measure for LRO

Truck Issues – Fix It Right the First Time (new issues in bold)
Reference
Model Year(s) Vehicle Line(s) / Condition Do This Don’t Do This Information / Bulletin
2004 Tahoe, Suburban, Silverado, Yukon, Re-flash passenger door module. Don’t replace passenger door 04-08-52-005
Yukon XL, Sierra, Escalade, Escalade module.
EXT, Escalade ESV, H2 – Passenger Door
Module and RKE Inoperative
2002-2004 Chevrolet Silverado, GMC Sierra – Replace accumulator and/or Don’t replace compressor. 02-01-38-007C
Accumulator/Accumulator Bracket accumulator bracket.
2001-2003 Fullsize Pickups – Injector Use Corporate Bulletin Number 04-06-04-007A Don’t replace 8 injectors for any complaint Special Policy 04039
Replacement for High Flow Rates for injectors with high fuel return rates. Use other than high fuel return rates. All other
Special Policy 04039 for all 01-02 vehicles. injector failures are fix as failed.
2004-2005 All Cars and Trucks – State-of-Charge Check battery’s state-of-charge per Don’t remove and replace battery. 02-06-03-009A
Upon Delivery of New Vehicle revised PDI procedure using
Midtronics Conductance Tester.
2002-2004 Fullsize and Midsize Pickups and When submitting claims for reprogramming an Don’t use K5364, which is for repro- 02-04-21-006D
Utilities – Labor Operation Assignments electronic module, use correct labor operation gramming transmission control module 02-06-04-057D
for Control Module Reprogramming that reflects the module being programmed. (TIM), when reprogramming TCCM.
2002-2004 Fullsize and Midsize Pickups and Verify sleepy module as primary cause. Don’t replace encoder motor or transfer 02-04-21-006D
Utilities – Sleepy New Venture Gear Reprogram TCCM with latest software case. Replace the module only if C0550
Transfer Case Control Module released 3/11/04. DTC shows as current or in history.
2002-2003 Chevrolet Avalanche and Cadillac Thoroughly clean, dry and treat Don’t replace cargo covers for this 04-08-111-001A
Escalade EXT – Cargo Covers and components with “Armor-dillo.” condition.
Cladding Faded or Stained
2002-2004 All Passenger Cars and Trucks – Air Follow SI and bulletin for diagnostic infor- Don’t replace air conditioning 01-01-38-013A
Conditioner Compressor Diagnosis mation before compressor replacement. compressor. 03-01-38-019
2002-2004 All TrailBlazers, Envoy, Envoy XL, Bravada – Lubricate and remove material, Don’t replace upper or lower 02-02-35-006A
Squeak/Rub/Scrub Type Noise in Steering Column per bulletin. intermediate shaft.
2001-2004 Fullsize Pickups and Utilities – Replace individual parts as needed. Don’t replace complete mirror 03-08-64-028
Servicing Wide Load Mirrors (RPO DPF) assembly.

Know-How 10290.02D Emerging Issues February 10, 2005, 9:00 AM, 11:30 PM, and 3:30 PM Eastern Time
Broadcasts New Model Features and Stay tuned! These programs will return soon.
for Technology Close-Up seminars Check the Service Know-How section of the GM Training
website (www.gmtraining.com) for more details.
February
– Thanks to Tracy Timmerman
8