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INTRODUCTION

ARROWS AND SYMBOLS

GENERAL INFORMATION

General Information - Volt

This service manual uses various symbols in order to describe different service operations.

image


Fig. 1: Identifying Different Service Operations Symbols Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Front of Vehicle

2

View Detail

Callout

Component Name

2

View Detail

3

Ambient Air Mixed with Another Gas or Indicate Temperature Change

4

Motion or Direction

5

View Angle

6

Dimension (1:2)

7

Ambient/Clean Air Flow or Cool Air Flow

8

Lubrication Point - Oil or Fluid

9

Task Related

10

Sectioning (1:3)

11

Gas Other Than Ambient Air or Hot Air Flow

12

Lubrication Point - Grease or Jelly

13

Multidirectional Arrow


ACRONYMS AND UNITS

Acronyms

Acronym

Meaning

Definition


2WD


Two-Wheel Drive

Indicates that a vehicle has 2 driven wheels OR that a 4WD vehicle uses only 2 wheels for propulsion. So it can be the description of a vehicle configuration OR the operational mode of the drivetrain.


4WD


Four-Wheel Drive

Four-wheeled vehicle with a drivetrain that allows all four wheels to receive power from the engine simultaneously which provides better control on various surfaces. Can be used to describe the configuration of the vehicle OR as the operational mode of the drivetrain. 4WD vehicles usually can turn 2 wheels off to be in a 2WD mode. See also AWD.

A/C

Air Conditioning

The cooling and dehumidification of indoor air for thermal comfort.

A/D

Analog to Digital

Used in context of converting electrical analog signals to digital signals.


ABS


Antilock Braking System

System on motor vehicles which prevents the wheels from locking while braking which helps the driver maintain control in heavy braking conditions.

AC

Alternating Current

An electrical current whose magnitude and direction vary cyclically.

AM

Amplitude Modulation

Method of impressing data onto an alternating-current (AC) carrier waveform.

APP

Accelerator Pedal Position

A pedal that controls the throttle valve.


AWD


All-Wheel Drive

All-wheel-drive systems are designed to function on all types of surfaces, both on- and off-road, and most of them cannot be switched off. This can also be called full-time four wheel drive. See also 4WD.


Acronym

Meaning

Definition


AWG


American Wire Gauge

American wire gauge is a standardized wire gauge system used since 1857 predominantly in the United States for the diameters of round, solid, nonferrous, electrically conducting wire.

E.g. a wire of AWG10 has a diameter of 2.588mm,

AWG20 corresponds to a diameter of 0.812mm.

B+

Battery Positive Voltage

The electrical potential on the positive terminal of the battery.

BARO

Barometric Pressure

Atmospheric pressure as measured by a barometer.


BCM


Body Control Module

This module supplies vehicle occupants with visual and audible information and controls various vehicle functions,

BECM

Battery Energy Control Module

Control module used to regulate the battery voltage.

BPP

Brake Pedal Position

Position of the foot pedal that moves a piston in the master brake cylinder.

CAN

Controller Area Network

Serial data connection between control modules by Bosch


CCM


Chassis Control Module

The module that controls various vehicle functions on the Chassis, like Engine/Trans Mount, Active Grille Air Shutter, Load Leveling, etc•••

CD

Compact Disc

A small optical disk on which data such as music, text, or graphic images is digitally encoded.


CNG


Compressed Natural Gas

This a substitute for gasoline or diesel fuel. It is made by compressing natural gas (which is mainly composed by methane (CH4), in a percentage range of 70% to 98%)


CO


Carbon Monoxide

This is a product of the incomplete combustion of carbon-containing compounds, at room temperature this is a gas. It consists of one carbon atom covalently bonded to one oxygen atom.

CO2

Carbon Dioxide

Chemical compound composed of two oxygen atoms covalently bonded to a single carbon atom.


CPA


Connector Position Assurance

Part of an electrical connector that prevents the connector from moving out of its socket. Usually needs to be pressed to unlock the connector when disconnecting it.


CPP


Clutch Pedal Position

A lever operated with the foot that controls the coupling that connects or disconnects driving and driven parts of a driving mechanism.


CV


Constant Velocity

Used in conjunction with CV joints, which connect two shafts at an angle while both shafts always have the same rotational speed without variations.

CVT

Continuously Variable Transmission

A transmission in which the ratio of the rotational speeds of two shafts, as the input shaft and output


Acronym

Meaning

Definition



shaft of a vehicle or other machine, can be varied continuously within a given range, providing an infinite number of possible ratios which improves fuel economy.

D

Drive

D on the transmission gear selector lever.


DAB


Digital Audio Broadcast

Technology for broadcasting of audio using digital radio (carries information via digital signal) transmission.

DC

Direct Current

Continuous current, constant flow of electric charge.


DLC


Data Link Connector

This is an electronic connector typically located underneath the driver's side dashboard, just above the pedals. The connector has 16 pins.


DMM


Digital Multimeter

Electronic measuring instrument that combines several functions in one unit. The most basic instruments include an ammeter, voltmeter, and ohmmeter.


DOHC


Dual Overhead Camshaft

Dual overhead camshafts (DOHC) are higher performance engines, they produce more power, and can run at higher speeds because they allow an engine to have four valves per cylinder.

Each camshaft operates two of the valves, one camshaft handles the intake valves, and one handles

the exhaust valves

DPF

Diesel Particulate Filter

Device designed to remove diesel particulate matter or soot from the exhaust gas of a diesel engine.


DRL


Daytime Running Lamps

White lights mounted on the front of an automobile that automatically switch on when the key is turned and are intended for daytime use, to increase the visibility of the automobile.

DSCC

Distance Sensing Cruise Control

A type of cruise control that automatically maintains the distance between vehicles.


DSP


Digital Signal Processor

A specialized microprocessor designed specifically for digital signal processing, generally in real-time computing.


DTC


Diagnostic Trouble Code

An electronic signal stored in an automotive computer, indicating the presence of a fault detected by that computer.


DVD


DVD

A popular optical disc storage media format the size of a CD. Used mainly for movies but also for data. DVD has no spelled out version (officially it does not mean Digital Video Disc or Digital Versatile Disc, it just means DVD).

EBCM

Electronic Brake Control Module

This module contains a microprocessor and software for antilock braking system operation.


Acronym

Meaning

Definition


ECM


Engine Control Module

This electronic module works with a vehicle's sensors and engine control devices to insure that the engine operates at maximum efficiency and performance. It performs three vital functions. Receives electronic signals from engine sensors. Analyzes the data and makes an engine performance decision (based on the pre-set parameters within the unit). Sends an "output command" to an actuator that adjusts engine performance.


ECT


Engine Coolant Temperature

A measure of how hot or cold the fluid which flows through the engine in order to prevent its overheating, transferring the heat produced by the device to other devices that utilize or dissipate it.


EEPROM

Electrically Erasable Programmable Read-Only Memory

A non-volatile storage chip used in computers and other devices to store small amounts of volatile data,

e.g. calibration tables or device configuration.


EGR


Exhaust Gas Recirculation

Is an NOx (nitrogen oxide and nitrogen dioxide) reduction technique used in most gasoline and diesel engines. EGR works by recirculating a portion of an engine's exhaust gas back to the engine cylinders.


EMI


Electromagnetic Interference

Electromagnetic interference (also called radio frequency interference) is a disturbance that affects an electrical circuit due to either electromagnetic conduction or electromagnetic radiation emitted from an external source.

ESD

Electrostatic Discharge

The sudden and momentary electric current that flows between two objects at different electrical potentials.

EV

Electric Vehicle

A category of vehicles that only have an electric drive system.

EVAP

Evaporative Emission

A system that controls the fuel fumes in the fuel tank.


FM


Frequency Modulation

In telecommunication this is a way to convey information over a carrier wave by varying its frequency.


FWD


Front-Wheel Drive

A form of engine/transmission layout used in motor vehicles, where the engine drives the front wheels only.


GMLAN


General Motors Local Area Network

A local-area network is a computer network covering a small geographic area, like a home or vehicle. This specific type of LAN connects several controllers inside the vehicle and was developed by General Motors.


GPS


Global Positioning System

Satellite-based navigation system made up of a network of 24 satellites placed into orbit by the U.S. Department of Defense.


Acronym

Meaning

Definition

GSM

Global System for Mobile Communications

Globally accepted standard for digital cellular communication.


GVW


Gross Vehicle Weight

Maximum total weight of a road vehicle or trailer that is loaded, including the weight of the vehicle itself plus fuel, passengers, cargo, and trailer tongue weight.

HD

Heavy Duty

Robust design to accommodate large work loads.


HID


High Intensity Discharge

A type of light that produces a bright light by using gas filled bulbs. (gas is usually mercury, metal halide, and high-pressure sodium) Uses very little battery power and is a very "cool" light.


HO2S


Heated Oxygen Sensor

Heated oxygen sensors have an internal heater circuit that brings the sensor up to operating temperature more quickly than an unheated sensor. An oxygen sensor must be hot (about 600 - 650°F) before it will generate a voltage signal. The hot exhaust from the engine will provide enough heat to bring an O2 sensor up to operating temperature.


HVAC


Heating Ventilation Air Conditioning

This system is sometimes referred to as climate control. Ventilation air ducts installed throughout a vehicle that supply conditioned air to a room through rectangular or round outlet vents.


I2 C


Inter-Integrated Circuit

Serial data connection between Integrated Circuits (microchips) inside a control module invented by Phillips

IAT

Intake Air Temperature

Temperature of the air entering intake air flow system of the engine.


ICE


Internal Combustion Engine

An engine in which the combustion of fuel and an oxidizer (typically air) occurs in a confined space called a combustion chamber.


ID


Identification

Number or Code that identifies a component or control module. Can be written on the part or be transmitted on a bus or via radio.


ISP


Internet Service Provider

A company that furnishes corporations and individual consumers with various services, mainly access to the Internet.

ISS

Input Shaft Speed

Rotational speed of the input shaft of a transmission.

LAN

Local Area Network

Standard network connection PC's.


LCD


Liquid Crystal Display

A thin, flat display device made up of any number of color or monochrome pixels arrayed in front of a light source or reflector.


LED


Light Emitting Diode

Small light bulbs that fit easily into an electrical circuit they do not have a filament that will burn out, and they do not get especially hot. They are


Acronym

Meaning

Definition



illuminated solely by the movement of electrons in a semiconductor material.


LIN


Local Interconnect Network

Computer networking bus system used within automotive network architectures. Similar to CAN, but cheaper and less powerful.


LPG


Liquefied Petroleum Gas

A mixture of mainly propane and butane, produced commercially and stored under pressure to keep it in a liquid state.

MAF

Mass Air Flow

The amount of air drawn into the engine

MAP

Manifold Absolute Pressure

Pressure in the engine intake system after the throttle valve referenced to a perfect vacuum.

MDI

Multiple Diagnostics Interface

A device used by GM dealers that enables a PC to communicate with the control modules in a vehicle.

MIL

Malfunction Indicator Lamp

An indicator of the internal status of a car engine.

MOST

Media Oriented Systems Transport

Serial communication bus to transmit audio and video information.

N

Neutral

A state of the transmission in which it is not engaged.

NiMH

Nickel Metal Hydride

A type of rechargeable battery that uses a hydrogen absorbing alloy for the negative electrode.


NOx


Nitrogen Oxides

Refers to any of the following oxygen compounds of nitrogen or a mixture of them. Nitric Oxide, Nitrogen dioxide, Nitrous Oxide, Dinitrogen trioxide, Dinitrogen tetroxide, Dinitrogen pentoxide.


O2


Oxygen

A colorless, odorless, tasteless, gaseous chemical element with the chemical symbol O and atomic number 8.

O2S

Oxygen Sensor

An electronic device that measures the proportion of oxygen (O2) in the gas or liquid being analyzed.

OBD

On-Board Diagnostic

A generic term referring to a vehicle's self-diagnostic and reporting capability.


OEM


Original Equipment Manufacturer

A producer that provides a product to its customers, who proceed to modify or bundle it before distributing it to their customers.

OSS

Output Shaft Speed

Rotational speed of the output shaft of a transmission.

P

Park

A state in which the transmission is set so one can leave the vehicle.

PCB

Printed Circuit Board

A thin plate on which chips and other electronic components are placed.

PCM

Powertrain Control Module

A control module that features the functions of both, the engine and the transmission control module.


PCMCIA


Personal Computer Memory Card Industry Association

An international standards body and trade association with over 100 member companies that was founded in 1989 to establish standards for Integrated Circuit cards and to promote interchangeability among


Acronym

Meaning

Definition



mobile computers where ruggedness, low power, and small size were critical.


PIN


Personal Identification Number

A secret numeric password shared between a user and a system that can be used to authenticate the user to the system.


PPE


Personal Protective Equipment

Protective clothing, helmets, goggles, or other garment designed to protect the wearer's body from injury.

PRNDL

Park, Reverse, Neutral, Drive, Low

Park, Reverse, Neutral, Drive, Low (automatic transmission positions).

PTC

Positive Temperature Coefficient

Refers to materials that experience an increase in electrical resistance when their temperature is raised.


PTO


Power Take-Off

A splined driveshaft, usually on a tractor or truck that can be used to provide power to an attachment or separate machine. This mechanism allows implements to draw energy from the tractor's engine.

PVC

Polyvinyl Chloride

A thermoplastic copolymer.

PWM

Pulse Width Modulation

Square shaped type of signal that carries the information in the ratio between on and off times.

R

Reverse

Rearward: directed or moving toward the rear;


RAM


Random Access Memory

A type of computer data storage. It today takes the form of integrated circuits that allow the stored data to be accessed in any order.


RCT


Radiator Coolant Temperature

This is the heat intensity of the radiator coolant measured in degrees. The radiator is a part of the cooling system that removes the engine heat. Coolant is a mixture of water and antifreeze (ethylene glycol) which lowers the freezing point of the water in the coolant system, this fluid also picks up heat from the engine and transfers it to the air.


RDS


Radio Data System

A standard from the European Broadcasting Union for sending small amounts of digital information using conventional FM radio broadcasts.


RF


Radio Frequency

A frequency or rate of oscillation within the range of about 3 Hz and 300 GHz. This range corresponds to frequency of alternating current electrical signals used to produce and detect radio waves.


ROM


Read-Only Memory

A class of storage media used in computers and other electronic devices. Data stored in ROM cannot be modified.


RPO


Regular Production Option

A three digit/letter code given to parts, assemblies, and systems originally installed on the vehicle. These RPO codes designate options and are assigned by General Motors.


Acronym

Meaning

Definition


RSA


Rear Seat Audio

An auxiliary set of controls that operate the main audio system from the rear seat. Rear passengers can also operate a different media source than the front passengers.


RWD


Rear-Wheel Drive

A common engine/transmission layout in which the engine is in the front of the vehicle, but the front mid- engine, rear mid-engine and rear engine layouts are also used.


SCV


Speed Controlled Volume

The volume control is set for a desired sound level in the vehicle as the vehicle increases its speed, the sound level is adjusted.

SDM

Sensing and Diagnostic Module

The name given to air bag modules used in General Motors vehicles.


SIM


Subscriber Identity Module

Part of a removable smart card Integrated Circuit Card. This is used for mobile cellular telephone devices such as mobile computers and mobile phones. SIM cards securely store the service-subscriber key used to identify a subscriber. The SIM card allows users to change phones by simply removing the SIM card from one mobile phone and inserting it into another mobile phone or broadband telephony device.


SIR


Supplemental Inflatable Restraint

Technical term for the air bag. Air bag is a stretchable membrane, which inflates during an automobile accident to provide cushioning to the passenger's head and torso to prevent injury to the passengers.


SPI


Serial Peripheral Interface

This is an interface that enables the serial (one bit at a time) exchange of data between two devices. An SPI operates in full duplex mode. This means that data can be transferred in both directions at the same time. It is a standard bus technology like CAN or I2C.

SPS

Service Programming System

System that enables repair facilities to update the software in control modules.


SUV


Sport Utility Vehicle

A passenger vehicle which combines the towing capacity of a pickup truck with the passenger-carrying space of a minivan.

SVS

Service Vehicle Soon

Indicator lamp or symbol for a malfunction related to a vehicle component or system.


TA


Traffic Announcement

Message spoken on radio regarding the movement of vehicles or pedestrians through an area or along a route. The buttons on radios that enable this announcements are also often labeled TA.


TAC


Throttle Actuator Control

A motor which moves the engine throttle plate or valve, controlled by the engine control module. A throttle plate limits the amount of air entering a internal combustion gasoline engine.


Acronym

Meaning

Definition


TAP


Transmission Adaptive Pressure

The transmission control module learns each component's characteristics and adjusts fluid pressure accordingly.


TCC


Torque Converter Clutch

Resides in a torque converter to connect an engine to an automatic transmission. The clutch is applied when conditions are correct to achieve a 1:1 ratio of engine crankshaft to transmission input shaft.


TCM


Transmission Control Module

A module that controls electronic automatic transmissions. It uses sensors from the vehicle as well as data provided by the Engine Control Module to calculate how and when to change gears in the vehicle for optimum performance, fuel economy and shift quality.

TDC

Top Dead Center

The piston is in its highest position relative to the combustion chamber.


TIS


Techline Information System

The PC-based global dealership diagnostic software that provides the technician the ability to reference the most recent service information via the service department's computer.

TPA

Terminal Position Assurance

An additional locking mechanism inside an electric connector that holds the pins in place.

TV

Television

A telecommunication system for broadcasting and receiving moving pictures and sound over a distance.

USB

Universal Serial Bus

A type of communication bus connection between a computer and a peripheral device.


VCI


Vehicle Communications Interface

A diagnostic tool that communicates to modules of multiple communication protocols in a vehicle by converting vehicle serial data into PC serial data communication.

VIN

Vehicle Identification Number

Used by manufacturers to uniquely identify motor vehicles using 17 characters.


VSCM


Vehicle Stability Control Module

This module uses information from several sensors to detect a loss of vehicle traction, then works with the antilock brake system to apply individual brakes to help keep the vehicle on its intended path.


VSS


Vehicle Speed Sensor

Sends data regarding how fast the car is traveling at the moment of driving. It is designed to be able to record the rate at which the vehicle's crankshaft is spinning.


WOT


Wide Open Throttle

When the throttle blade or valve is at its maximum open position, allowing maximum air to enter an internal combustion gasoline engine.

WLAN

Wireless Local Area Network

Standard to transmit digital data via radio frequency.

Acronym

Meaning

Definition


XM


XM (Satellite Radio)

XM Satellite Radio Holdings (XM) is one of two satellite radio services in the United States and Canada. XM provides pay-for-service radio, analogous to cable television. Its service includes 73 different music channels, 39 news, sports, talk, and entertainment channels, 21 regional traffic and weather channels and 23 play-by-play sports channels (2008).


XML


Extensible Markup Language

A markup language that defines a set of rules for encoding documents in a format that is both human- readable and machine-readable.

Units

Unit

Meaning

Definition

m2

Square Meter

Area

A

Ampere

Electrical

Ah

Ampere Hour

Electrical

C

Coulomb

Electrical

dBm

Decibel Meter

Electrical

dBmV

Decibel Millivolt

Electrical

mV/DIV

Millivolts per Division

Electrical

mV/s

Millivolts per Second

Electrical

Ohm

Electrical

V

Volt

Electrical

V/DIV

Volts per Division

Electrical

V/ms

Volts per Millisecond

Electrical

W

Watt

Electrical

mm3 /stroke

Cubic Millimeters per Stroke

Flow

gal/h

Gallons per Hour

Flow

g/s

grams per second

Flow

g/stroke

Grams per Stroke

Flow

kg/100km

Kilograms per 100 Kilometer

Flow

kg/h

Kilograms per Hour

Flow

km/L

kilometer/liter

Flow

L/100km

Liters per 100 Kilometers

Flow

L/h

Liters per Hour

Flow

L/min

Liters per Minute

Flow

MPG

Miles per Gallon

Flow

mg/s

Milligrams per Second

Flow

mg/stroke

Milligrams per stroke

Flow

ft

feet

Length

in

Inch

Length


Unit

Meaning

Definition

m

Meter

Length

mi

Mile

Length

bar

Bar

Mechanical

bar/min

Bars per Minute

Mechanical

in. H2O

Inches of Water

Mechanical

in. H2O/s

Inches of Water per second

Mechanical

kPa/s

Kilopascals per Second

Mechanical

N

Newton

Mechanical

Â

Newton Meter

Mechanical

Pa

Pascal

Mechanical

Pa/s

Pascals per Second

Mechanical

lb ft

Pound Foot

Mechanical

PSI

Pound-Force per Square Inch

Mechanical

Counts

Counts

Misc.

Cycles

Cycles

Misc.

dB

Decibel

Misc.

°

Degree

Misc.

°C

Degree Centigrade

Misc.

°CA

Degree Crankshaft Angle

Misc.

°F

Degree Fahrenheit

Misc.

°/s

Degree per Second

Misc.

Hz

Hertz

Misc.

kbit/s

Kilobit per second

Misc.

lx

Lux

Misc.

ppm

Parts per Million

Misc.

%

Percent

Misc.

%/min

Percents per Minute

Misc.

%/sec

Percents per Second

Misc.

Pulses

Pulses

Misc.

:1

Ratio

Misc.

RPM

Revolutions per Minute

Misc.

Steps

Steps

Misc.

W/m2

Watts per Square Meter

Misc.

g

g (Acceleration)

Movement

km/h

Kilometers per Hour

Movement

m/s

Meters per Second

Movement

m/s3

Meters per Second Cubed

Movement

m/s2

Meters per Second Squared

Movement

MPH

Miles per Hour

Movement

mm/s

Millimeters per Second

Movement

Unit

Meaning

Definition

d

Day

Time

h

Hour

Time

hh:mm:ss

Hour:Minute:Second

Time

ms/DIV

Milliseconds per Division

Time

min

Minute

Time

s

Second

Time

s/DIV

Seconds per Division

Time

yy-mm-dd

Year-Month-Day (2 digits)

Time

yyyy-mm-dd

Year-Month-Day (4 digits, preferred)

Time

m3

Cubic Meter

Volume

gal

Gallon

Volume

L

Liter

Volume

mL

milliliters

Volume

US gal

US Gallon

Volume

US pt

US Pint

Volume

US qt

US Quart

Volume

kg

Kilogram

Weight


TEXT FORMATS AND SYMBOLS

These punctuation marks and symbols are used in the service information to separate information, values, data, and text.


NOTE: In the examples, the punctuation marks and symbols are bold only to highlight them; in the service information, they are not bold.


Punctuation/Symbol

Description


:

Colon separates the "what to do" statement from the "where to do it, how to do it, or which ones"

Example:

image Disconnect the electrical connector : X3 @ K20 Engine Control Module

image Test for less than 10 Ω between the test points : Signal circuit terminal 1 & Ground

image Install the following components : image Valve

image Bolt [ 2x ] image Nut [ 2x ]


&

Ampersand separates two test points or two or more conditions

Example:

image Test for less than 10 Ω between the test points: Signal circuit terminal 1 &


Punctuation/Symbol

Description


Ground

image Throttle Angle = Greater than 0% & Engine Speed = Less than 1000 RPM


@

At sign separates location information relative to a component. Replaces "from the", "to the" or "at the".

Example:

image Signal circuit terminal 1 @ Control module harness

image Instrument Panel Center Trim Plate Applique @ Instrument Panel - Remove


-

Chevron separates the action/condition/function/object from the object/task

/value

Example:

image Perform the scan tool control function: EVAP Purge Solenoid Valve - 50% image Remove - Test Lamp

image Test or replace - B34 Engine Coolant Temperature Sensor

image Instrument Panel Center Trim Plate Applique @ Instrument Panel -

Remove

image If any of the DTCs are set - Repeat Step 5


=

Equal sign separates the observed object from the nominal value or when stating a value

Example:

image Verify the scan tool parameter: ECT Sensor = Colder than -39°C (-38°F)

image Engine Run Time = Greater than 10 min

image

0.75 to 1.5 V - A/C Compressor = Off

image

1.3 to 2.5 V - A/C Compressor = On


-

Hyphen separates the component name from the location information relative to the vehicle (eg. Left, Right, Lower, Upper)

Example:

Cylinder Head - Left - Remove


-

Minus sign used for negative values

Example:

Engine Coolant Temperature= Between- 10 and - 5°C (14 and 23°F)


-

Ndash separates a consecutive numeric range

Example:

Cylinder 1- 8 Injector


-

Mdash separates additional information at the end of the subject matter

Example:

Punctuation/Symbol

Description


image Engine Controls Ignition Relay Feedback Circuit = Less than 5 V - For greater than 5 s

image Switch @ Switch Bezel - Remove - Rotate counterclockwise


/

Forward slash separates conditions or alphanumeric terminals

Example:

image Screen - Misaligned / Missing / Restricted / Torn

image Signal circuit terminal 1 / A @ Control module harness


( )

Parenthesis identify a callout reference

Example:

Instrument Panel Center Trim Plate Applique ( 1 )


[ ]

Brackets identify a quantity reference

Example:

Hood Hinge Bolt [ 2x ]


{ }

Curly brackets identify decisional information at the beginning of a subject matter

Example:

image { If equipped } Instrument Panel Center Trim Plate Applique (1) - Remove

image { 2.0L (LHU) } Low Reference circuit terminal 2 & Ground

image { 2.4L (LAF) } Low Reference circuit terminal 5 & Ground

GRAPHIC COLORS AND GRAPHIC SYMBOLS

Graphic Colors - General

image

Fig. 2: Graphic Colors - General

Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Orange - High voltage electrical connectors and harnesses being removed or installed.

2

Green - Electrical connectors and harnesses being removed or installed.

3

Red - Fasteners being removed or installed.

4

Dark Gray - Standout color that shows the component being removed or installed.

5

Light Gray - Background detail to show component location.

6

Light Blue - Special tool being used.

Graphic Symbols - Collision Repair

image

Fig. 3: Graphic Symbols - Collision Repair Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Drill through top layer of material only

2

Structural Rivet

3

Sectioning Location

4

Drill Hole

5

Mig Braze Slot

6

Self-Piercing Rivet

7

Mig/Mag Plug Weld

8

Adhesive

9

Apply Heat

10

Resistance Spot Weld

CUSTOMER CONCERN VERIFICATION SHEETS

The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time.

The GM-wide Customer Concern Verification Sheets are available in GM GlobalConnect. The Customer Concern Verification Sheets may be printed and reproduced locally.

TRAINING

Dealers


All U.S. GM Dealers participating in the Center of Learning / GM Service Technical College (STC) Programs can enroll through the Center of Learning website at https://www.centerlearning.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual and their job role. Dealers who have questions about Center of Learning Training should contact the Center of Learning help desk at 1-888-748-2687. The help desk is available Monday through Friday, 8:00 am - 9:00 pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at

1-888-337-1010.

Fleets


GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through the Center of Learning/GM Service Technical College (STC).

Assistance for GM fleet registered customers using GM STC training is provided by the Center of Learning help desk at 1-888-748-2687. The help desk is available Monday through Friday, 8:00 am - 9:00 pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at

1-888-337-1010.

Most GM STC course materials have associated charges.

To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831.

Non-GM Dealer Technicians


Technician training for non-GM dealers is available through ACDelco. This training is for ACDelco PSC and Fleet program members employed in the automotive or truck service industry.

ACDelco courses are available at approved GM STC Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 (prompt 1) or contact us via the web at www.acdelcotechconnect.com and select the Training tab. Seminars are also offered through the ACDelco Warehouse Distribution channel.

Contact your Local ACDelco representative or distributor directly for more information.

VEHICLE, ENGINE AND TRANSMISSION ID AND VIN LOCATION, DERIVATIVE AND USAGE

VIN Plate

image


Fig. 4: View Of VIN Plate Location

Courtesy of GENERAL MOTORS COMPANY

The vehicle identification number (VIN) plate (1) is the legal identifier of the vehicle. The VIN plate is located on the upper left corner of the instrument panel (I/P) and can be seen through the windshield from the outside of the vehicle.

VIN Body Stamping

image


Fig. 5: VIN Body Stamping

Courtesy of GENERAL MOTORS COMPANY

The stamping is located on the front floor panel under the front right-hand floor mat. It can be seen under the VIN Plate Opening Access Cover (1).


Position

Definition

Character

Description

1

Region of Build

1

United States

2

Manufacturer

G

General Motors

3

Make

1

Chevrolet Passenger Car


4-5


Vehicle Line/Series

R/A

Volt LT, Standard Emissions Package

R/B

Volt Premier, Standard Emissions Package

R/C

Volt LT, Low Emissions Package

R/D

Volt Premier, Low Emissions Package

R/9

Volt (Non US, Non Canada)

6

Body Style

68

Sedan, 4 - Door, 6 Window, Plain Back, (H/Back)

Position

Definition

Character

Description


7


Restraint System


S

AYF - Active Manual Belts, Airbags - Driver & Passenger Front (1st row), Front Seat Side (1st row) & Rear Seat Side (2nd row), Roof Side (all seating rows), Driver & Passenger knee (1st row)

8

Engine Type

5

L3A - ENGINE GAS, 4 CYL, 1.5L, DI, DOHC, VVT, HYBRID, GEN 1

9

VIN Check Digit

Varies

Calculated Check Digit

10

Model Year

H

2017

11

Plant Location

U

Detroit Hamtramack

12 - 17

Production Sequence Number

-

Production Sequence Number

1.5L (L3A) Engine ID and VIN Derivative Location

Refer to Engine Identification .

Transmission ID and VIN Derivative Location

Refer to Transmission Identification Information .

VEHICLE CERTIFICATION, TIRE PLACARD, ANTI-THEFT, AND SERVICE PARTS ID LABEL

image


Fig. 6: Identifying Vehicle Certification, Tire Place Card, Anti-Theft & Service Parts ID Labels Courtesy of GENERAL MOTORS COMPANY


Callout

Description

Vehicle Certification Label

The vehicle certification label is located on the driver side B pillar and displays the following assessments:

image Gross Vehicle Weight Rating (GVWR)

image Gross Axle Weight Rating (GAWR), front and rear

image The gross vehicle weight (GVW) is the weight of the vehicle and everything it carries. The gross vehicle weight must not exceed the Gross Vehicle Weight Rating. Include the following items when figuring the GVW:

image The base vehicle weight (factory weight) image The weight of all vehicles accessories

image The weight of the driver and the passengers image The weight of the cargo

1

Name of Manufacturer

Callout

Description

2

Gross Vehicle Weight Rating

3

Gross Axle Weight Rating (Front, Rear)

4

Canadian Safety Mark (w/RPO Z49)

5

Certification Statement

6

Vehicle Class Type (Pass Car, etc.)

7

Vehicle Identification Number

8

Date of Manufacture (Mo/Yr)

Tire Placard

The tire placard label is located on the driver side B pillar and displays the following assessments:

9

Specified Occupant Seating Positions

10

Maximum Vehicle Capacity Weight

11

Tire Pressure, Front, Rear, and Spare (Cold)

12

Original Equipment Tires Size

Service Parts ID Label

The vehicle service parts identification label is located in the rear compartment in the right hand quarter stowage pocket. The label is use to help identify the vehicle original parts and options.

13

Vehicle Identification Number

14

Engineering Model Number (Vehicle Division, Line, and Body Style)

15

Interior Trim Level and Decor

16

Exterior (Paint Color) WA Number

17

Paint Technology

18

Special Order Paint Colors and Numbers

19

Vehicle Option Content

Anti-Theft Label


20

The Federal law requires that General Motors label certain body parts on this vehicle with the VIN. The purpose of the law is to reduce the number of motor vehicle thefts by helping in the tracing and recovery of parts from stolen vehicles.

Labels are permanently affixed to an interior surface of the part. The label on the replacement part contains the letter R, the manufacturer's logo, and the DOT symbol. The anti-theft label must be covered before any painting, rustproofing procedures, and uncovered after the procedures. Failure to follow the precautionary steps may result in liability for violation of the Federal Vehicle Theft Prevention Standard and possible

suspicion to the owner that the part was stolen.


RPO CODE DESCRIPTION


RPO

Description

4AA

INTERIOR TRIM-JET BLACK

4EL

INTERIOR TRIM-JET BLACK/BRANDY

4H5

INTERIOR TRIM-DARK ASH GRAY/LIGHT ASH GRAY

5A7

WHEEL SPARE-NONE

5CL

ACCESSORY-CHARGE CORD SET MODE3 CHARGING - KOREAN STANDARD TO TYPE 1 VEHICLE


RPO

Description

5GP

TIRE ALL-215/50R17 SL 91 H BW ALS

5XB

ACCESSORY-CHARGE CORD SET - 110/120V - STANDARD

62G

ACCESSORY-ACCENT LIGHTING - FRONT EXTERIOR

9L3

TIRE SPARE-NONE

A51

SEAT-FRT BKT, CUSTOM

ACO

IDENTIFICATION-ACCESSORY CATALOG OFFERING

AG6

ADJUSTER PASS ST-MANUAL, 4 WAY

AH3

ADJUSTER FRT ST-MANUAL, 4 WAY, DRIVER

AJC

RESTRAINT-HEAD, FRT SEAT, UP/DOWN ADJUSTMENT

AL0

SENSOR INDICATOR-INFLATABLE RESTRAINT, FRT PASS/CHILD PRESENCE DETECTOR

AXJ

VEHICLE TYPE-PASSENGER CAR

AYF

RESTRAINT SYSTEM-SEAT, INFLATABLE, DRIVER & PASS FRT, FRT SEAT SIDE & RR SEAT SIDE, ROOF SIDE, KNEE

BTT

ALARM-REMOTE PANIC

C68

HVAC SYSTEM-AIR CONDITIONER FRT, AUTO, ELECTRONIC CONTROLS

CV3

COUNTRY-MEXICO

CW1

COUNTRY-KOREA

D31

MIRROR I/S R/V-TILT

D71

MIRROR O/S-LH & RH, REMOTE CONTROL, ELECTRIC, MANUAL FOLDING

DD8

MIRROR I/S R/V-LT SENSITIVE

DEH

PLANT CODE-DETROIT/HAMTRAMCK, MI, USA

DLW

MIRROR O/S-LH & RH, REMOTE CONTROL, ELECTRIC, MANUAL FOLDING, HEATED

EF7

COUNTRY-UNITED STATES OF AMERICA (USA)

EVS

PROP ENGY STOR PACK-PROPULSION BATTERY, LI, 370V, 50AH, UNDERBODY

EXP

EXPORT-

FE2

SUSPENSION SYSTEM-RIDE, HANDLING

FE9

CERTIFICATION-EMISSION, FEDERAL

FHO

VEHICLE FUEL-GASOLINE E10

FXJ

RATIO-TRANSAXLE FINAL DRIVE 2.64

G1E

PRIMARY COLOR-EXTERIOR, LIMITED ADDICTION RED TINT (405Y)

G1W

PRIMARY COLOR-EXTERIOR, ABALONE WHITE TRICOAT(140X)

GA1

PRIMARY COLOR-EXTERIOR, JADED MET (378A).

GA6

PRIMARY COLOR-EXTERIOR, YOU DRIVE ME GRAZY MET (380A)

GAN

PRIMARY COLOR-EXTERIOR, SWITCHBLADE SILVER MET (G) 636R

GAZ

PRIMARY COLOR-EXTERIOR, SUMMIT WHITE (G) 8624

GB8

PRIMARY COLOR-EXTERIOR, BLACK MEET KETTLE MET (384A)


RPO

Description

GD1

PRIMARY COLOR-BLUE ME AWAY MET (388A)

GMU

PRIMARY COLOR-EXTERIOR, PEPPERDUST MET-2 (441B)

H0Y

INTERIOR TRIM CONFIG-LEATHER, LEVEL 1, JET BLACK

H1T

INTERIOR TRIM CONFIG-CLOTH, LEVEL 1, JET BLACK

H81

INTERIOR TRIM CONFIG-CLOTH, LEVEL 1, DARK ASH GRAY/LIGHT ASH GRAY

H82

INTERIOR TRIM CONFIG-LEATHER LEVEL 1, DARK ASH GRAY/LIGHT ASH GRAY

H83

INTERIOR TRIM CONFIG-LEATHER LEVEL 1, JET BLACK/BRANDY

I17

ENGINEERING YEAR-2017

IO5

RADIO-INFOTAINMENT SYSTEM - UPLEVEL HMI, ENHANCED CONNECTIVITY

IO6

RADIO-INFOTAINMENT SYSTEM - UPLEVEL HMI, ENHANCED CONNECTIVITY, EMBEDDED NAVIGATION

J67

BRAKE SYSTEM-POWER, FRT & RR DISC, ABS, 15"

K34

CRUISE CONTROL-AUTOMATIC, ELECTRONIC

K4C

CHARGER-INDUCTIVE PORTABLE WIRELESS DEVICE

KA1

HEATER SEAT FRT-DRVR & PASS

KA6

HEATER SEAT-REAR

KSG

CRUISE CONTROL-AUTOMATIC, ADAPTIVE, WITH STOP/GO

KTI

KIT, TIRE-INFLATOR

L3A

ENGINE-GAS, 4 CYL, 1.5L, DI, DOHC, VVT, HYBRID, GEN 1

LHD

VEHICLE DRIVE-LEFTHAND DRIVE

MKV

TRANSMISSION-AUTO, ELECTRIC MOTOR, GM, GFE E REV DRIVE UNIT, X40F

N30

STEERING WHEEL-DELUXE


NE1

CERTIFICATION-EMISSION, GEOGRAPHICALLY RESTRICTED REGISTRATION FOR VEHICLES UP TO 14, 000 LBS GVW (USE 2003 MDL YR

NTB

EMISSION SYSTEM-FEDERAL, TIER 3

NU6

EMISSION SYSTEM-CALIFORNIA, PZEV

NUF

EMISSION SYSTEM-CALIFORNIA, ULEV125

NUL

EMISSION SYSTEM-KOREAN, SULEV30

RSB

WHEEL-17 X 7.0, J, ALUMINUM, DESIGN 1

RTN

WHEEL-17 X 7.0, J, ALUMINUM, DESIGN 2

RVW

ACCESSORY-BAG - TRUNK/CARGO AREA ORGANIZER

RWJ

ACCESSORY-COVER - VEHICLE - OUTDOOR, DESIGN 1

RWS

ACCESSORY-FLOOR MATS - CARPET

RWU

ACCESSORY-CARGO AREA ORGANIZER - COLLAPSIBLE

RYT

ACCESSORY-FIRST AID KIT

S08

ACCESSORY-HIGHWAY SAFETY KIT


RPO

Description

S4X

ACCESSORY-MIRROR COVERS/SKULL CAPS - ALTERNATE FINISH - PAINTED

SBZ

ACCESSORY-SPORT PEDAL KIT

SDI

ACCESSORY-TRIANGLE - REFLECTIVE

SFE

ACCESSORY-WHEEL LOCKS

SFJ

ACCESSORY-WINDOW SHADES - REFLECTIVE

SFS

ACCESSORY-SUN SHADES - REAR WINDOW

SFZ

ACCESSORY-EMBLEM - EXTERIOR - DESIGN 1

SH4

ACCESSORY-ILLUMINATED CUPHOLDERS AND FOOT WELLS

SIF

ACCESSORY-RSE - PORTABLE MEDIA CONNECTIVITY PACKAGE

SJH

ACCESSORY-WHEEL - 17 X 7.0 - J - ALUMINUM - DESIGN 1

TDM

MODE-TEEN DRIVER SETTINGS

TQ5

HEADLAMP HIGH BEAM-AUTO CONTROL

U2K

DIGITAL AUDIO SYSTEM-S-BAND

UE1

COMMUNICATION SYSTEM-VEHICLE, ONSTAR

UE4

SENSOR INDICATOR-FOLLOWING DISTANCE

UEU

SENSOR INDICATOR-FORWARD COLLISION ALERT

UFG

SENSOR INDICATOR-REAR CROSS TRAFFIC ALERT

UFQ

PARK ASSIST-FRONT, REAR, LATERAL-FRONT (SEMIAUTOMATIC STEERING ADVANCED PARKING AID)

UGN

COLL IMMINENT BRK-ALL SPEED, VEH FWD MOVEMENT, BRAKE PREFILL, INTEGRATED BRAKE ASSIST

UHS

DISPLAY INSTRUMENT-DRIVER INFO ENHANCED (MULTI COLOR ENHANCED GRAPHIC)

UHX

LANE ACTIVE SAFETY-KEEP ASSIST

UHY

COLL IMMINENT BRK-LOW SPEED, VEH FWD MOVEMENT, BRAKE PREFILL, INTEGRATED BRAKE ASSIST

UJM

TIRE PRESS INDICATOR-MANUAL LEARN

UKC

SIDE ACTIVE SAFETY-OBSTACLE DETECTION ENHANCED

UQA

SPEAKER SYSTEM-PREMIUM AUDIO BRANDED WITH AMPLIFIER

UVC

VISION-REAR VIEW, MONO, ANALOG

UVD

STEERING WHEEL HEAT-MANUAL

UZ6

SPEAKER SYSTEM-6, PREMIUM

V7X

SALES PACKAGE-#1

V7Y

SALES PACKAGE-#2

V8C

VEHICLE STATEMENT-MEXICO

V8D

VEHICLE STATEMENT-US

V8E

VEHICLE STATEMENT-CANADA

V8Y

VEHICLE STATEMENT-KOREA-FTA

VAV

ACCESSORY-FLOOR MATS - ALL WEATHER

VJQ

HOOK-TOW, FRT

RPO

Description

VK3

LICENSE PLATE FRONT-FRT MOUNTING PKG

VKX

ACCESSORY-SPARE WHEEL & TIRE

VLI

ACCESSORY-MAT - TRUNK / CARGO AREA

VMA

LICENSE PLATE FRONT-FRT MOUNTING PKG, KOREA

VPH

VEHICLE PREPARATION-OVERSEAS DELIVERY

VST

ACCESSORY-SILL PLATES - ALTERNATE DESIGN 1

VV4

COMMUNICATION EQUIP-MOBILE INTERNET CONNECTIVITY

VY7

KNOB-TRANS CONT LEVER, LEATHER

VYW

ACCESSORY-FLOOR MATS - PREMIUM CARPET - DESIGN 1

W2D

ACCESSORY-CARGO NET

WMH

VIN MODEL YEAR-2017

XL8

FREQUENCIES RATING-433 MHZ

YF5

CERTIFICATION-EMISSION, CALIFORNIA

YM8

IDENTIFICATION-LIMITED PERSONALIZATION OPTION (LPO)

Z49

COUNTRY-CANADA

Z49

COUNTRY-CANADA


FASTENERS

Metric Fasteners


This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength.

A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive® or Type 1A cross-recess identifies a metric cross- recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive® recess head screws.

GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and

25.4 threads per inch replaced the English 1/4 - 20 and 1/4 - 28 screws. The thread pitch is midway between the English coarse and fine thread pitches.

Fastener Strength Identification

image


Fig. 7: Identifying Fastener Strength Marks Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

English Bolt, Grade 2 (Strength Class)

2

English Bolt, Grade 5 (Strength Class)

3

English Bolt, Grade 7 (Strength Class)

4

English Bolt, Grade 8 (Strength Class)

5

Metric Nut, Strength Class 9

6

Metric Bolts, Strength Class Increases as Numbers Increase

The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face.

The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following:

image Lower strength

image No numbered head marking system image Wrong thread pitch

The metric fasteners on GM products are designed to new, international standards. The following are the

common sizes and pitches, except for special applications:

image M6.0 X 1

image M8 X 1.25

image M10 X 1.5

image M12 X 1.75

image M14 X 2.00

image M16 X 2.00


Prevailing Torque Fasteners


Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening.

All Metal Prevailing Torque Fasteners

These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener.

Nylon Interface Prevailing Torque Fasteners

These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads.

Adhesive Coated Fasteners

These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener.


image


Fig. 8: Identifying Adhesive Coated Fasteners Courtesy of GENERAL MOTORS COMPANY


Callout

Component Name

1

Prevailing Torque Nut, Center Lock Type

2

Prevailing Torque Nut, Top Lock Type

3

Prevailing Torque Nut, Nylon Patch Type

4

Prevailing Torque Nut, Nylon Washer Insert Type

5

Prevailing Torque Nut, Nylon Insert Type

6

Prevailing Torque Bolt, Dry Adhesive Coating Type

7

Prevailing Torque Bolt, Thread Profile Deformed Type

8

Prevailing Torque Bolt, Nylon Strip Type

9

Prevailing Torque Bolt, Out-of-Round Thread Area Type

A prevailing torque fastener may be reused ONLY if:

image The fastener and the fastener counterpart are clean and not damaged

image There is no rust on the fastener

image The fastener develops the specified minimum torque against its counterpart prior to the fastener seating

Metric Prevailing Torque Fastener Minimum Torque Development


Application

Specification

Metric

English

All Metal Prevailing Torque Fasteners

image 6 mm

0.4 N.m

4 lb in

image 8 mm

0.8 N.m

7 lb in

image 10 mm

1.4 N.m

12 lb in

image 12 mm

2.1 N.m

19 lb in

image 14 mm

3 N.m

27 lb in

image 16 mm

4.2 N.m

37 lb in

image 20 mm

7 N.m

62 lb in

image 24 mm

10.5 N.m

93 lb in

Nylon Interface Prevailing Torque Fasteners

image 6 mm

0.3 N.m

3 lb in

image 8 mm

0.6 N.m

5 lb in

image 10 mm

1.1 N.m

10 lb in

image 12 mm

1.5 N.m

13 lb in

image 14 mm

2.3 N.m

20 lb in

image 16 mm

3.4 N.m

30 lb in

image 20 mm

5.5 N.m

49 lb in

image 24 mm

8.5 N.m

75 lb in

English Prevailing Torque Fastener Minimum Torque Development


Application

Specification

Metric

English


Application

Specification

Metric

English

All Metal Prevailing Torque Fasteners

image 1/4 in

0.5 N.m

4.5 lb in

image 5/16 in

0.8 N.m

7.5 lb in

image 3/8 in

1.3 N.m

11.5 lb in

image 7/16 in

1.8 N.m

16 lb in

image 1/2 in

2.3 N.m

20 lb in

image 9/16 in

3.2 N.m

28 lb in

image 5/8 in

4 N.m

36 lb in

image 3/4 in

7 N.m

62 lb in

Nylon Interface Prevailing Torque Fasteners

image 1/4 in

0.3 N.m

3 lb in

image 5/16 in

0.6 N.m

5 lb in

image 3/8 in

1 N.m

9 lb in

image 7/16 in

1.3 N.m

12 lb in

image 1/2 in

1.8 N.m

16 lb in

image 9/16 in

2.5 N.m

22 lb in

image 5/8 in

3.4 N.m

30 lb in

image 3/4 in

5 N.m

45 lb in

THREAD INSERTS

General Purpose Thread Repair Kits. These kits are available commercially. Repair Procedure

image


Fig. 9: Drilling & Tapping Damaged Threads Courtesy of GENERAL MOTORS COMPANY


WARNING: Refer to Safety Glasses Warning .


NOTE: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use.

Avoid any buildup of chips. Back out the tap every few turns and remove the chips.


1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth.

2. Drill out the damaged threads. Clean out any chips.

3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads.

image


Fig. 10: View Of Thread Insert

Courtesy of GENERAL MOTORS COMPANY

4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel.


NOTE: The insert should be flush to one turn below the surface.


5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert.

6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift.

REGISTERED AND NON-REGISTERED TRADEMARKS

Listed below are Registered Trademarks (®) or Non-Registered Trademarks (™) which may appear in this service manual.


A

AC®

ACCUTURN®


ACDelco®

Active Fuel Management™

Acuzinc®

Airbank®

Allison®

AMMCO®

AUTOFUSE®

AUTOTRAC®

B

Bendix®

Bluetooth®

BON-AMI®

Bosch®

Bose®

C

Caterpillar®

CAT®

C-Quam®

D

Delco®

Delco Bose®

Delco Electronics®

Delco Freedom®

Delco LOC II®

Delco Moraine®

Delco Remy®

Delco Sound®

Delco Supreme®

Delco Tech®

DELCORE®

Delphi®

DEX-COOL®

DEXOIL®

DEXRON®

DEXSTEER™

DNR®

Dolby®

DR®

Duracell®

Duraguard®

Durastop®

Duramax™


E

Eaton Corporation®

EMD®

ETR®

F

FLO-LITE®

G

General Motors®

GM®

GM Goodwrench Service®

GM Optikleen®

GM Parts™

GM Pass®

GM Ultralite®

GMAC®

Goodwrench®

GTP®

H

Homelink™

HYDRA-MATIC®

I

Illumination®

INSTA-TRAC®

Intune®

L

LOCTITE™

Lord Fusor™

M

MAGNASTEER®

Maxifuse®

Metripack®

Micropack®

Minifuse®

Mr Goodwrench®

N

Northstar®

O

OnStar®

Optikleen®

P

PASS-KEY®

PASS-KEYII®

PASSLOCK™

PK3®

Pozidriv®

Pro®

Q

Quad 4®

R

RAINSENSE™

Rapid Fire®

S

ScotchBrite™

Scotchguard™

Signals®

Sikkens™

Soft-Ray®

Solar-Ray®

Stabilitrak®

Sunrayce®

Superlube®

Syclone®

T

Tech 2®

Techline®

Teflon®

Tefzel®

Theft-I®

Theftlock®

Tiltmaster®

TORX®

Transjel®

Transguide®

Twilight Sentinel®

U

Ultralite®

V

Velcro®

W

Weatherpack™


DOOR LOCK AND IGNITION LOCK FOLDING AND NON-FOLDING KEY CUTTING

High Security keys are available from the service parts system.

Obtain the key code from the security card or from the GM Dealer World, Parts, Key Code Look Up system.

If you have the key code and access to a Triax-E., BD Laser or other code key cutting machine from the GM Dealer Equipment Catalog, you may cut a new key.

If you have the original key and access to a Matrix S, BD Laser or other key duplicating machine, you may duplicate the key.

If you do not have a high security key cutting machine, order the side cut key from the service parts system. Include the key code in the NOTE field. Indicate the timing and the method of the shipment.

Inspect the new key operation in the lock cylinder. Ensure the new key operates effectively.

FRONT SIDE DOOR LOCK CYLINDER CODING

Special Tools

BO-49753 Assembly Tool


image


Fig. 11: Identifying Lock Components Courtesy of GENERAL MOTORS COMPANY

The door lock cylinder uses 8 of the 8 cut positions. The tumbler positions are staggered from side to side, 4 on one side and 4 on the other, are not self-retaining, and are not snap in.


NOTE: All lock cylinders for side milled keys have right and left tumblers. The

location of the tooth of the tumbler determines whether it is right of left. Illustrations in this procedure show the right tumblers on the top and the left tumblers on the bottom. All tumblers are marked 1R, 1L, 2R, or 2L. The number being cut depth and the letter meaning right or left.


1. Hold the door lock cylinder (1) so the side with the 4 tumbler spring pockets faces up, pocket nearest to the cylinder head.

2. Insert the tumbler springs (2) into the 4 spring pockets. This side uses left tumblers.

3. Install the tumbler (3) for key cut position one in the slot nearest to the front of the lock cylinder. Install the remaining tumblers, key cut positions 3, 5, and 7, following the key code and same process. Press the tumblers in place until they are secure.

4. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flush with the lock cylinder body.

5. Turn the cylinder so the side with the 4 tumbler spring wells faces up. This side uses right tumblers.

6. Insert the tumbler springs into the 4 spring pockets.

7. The first tumbler closest to the front of the lock cylinder to be loaded will be the second key cut position, the second number in the key code. Install the remaining tumblers for the key cut positions 4, 6, and 8. Press the tumblers in place until they are secure.

8. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flush with the lock cylinder body.

9. Insert the key and lightly lubricate the cylinder body diameter and tumbler surfaces and a small amount in the head of the cylinder using the supplied grease.

10. Insert the sleeve (4) onto the cylinder assembly.

11. Insert the clutch (5) and driver (6) onto the cylinder (1).

image


Fig. 12: Loading Cylinder Into Special Tool Courtesy of GENERAL MOTORS COMPANY

12. Load the cylinder into the BO-49753 assembly tool so that the clutch (1) indexes with the notch in the opening of the tool (2).

image


Fig. 13: Loading Assembly Tool Into Vise Courtesy of GENERAL MOTORS COMPANY

13. Load the assembly tool with the lock cylinder into a vice and tighten the vice ONLY enough to hold the tool and lock the cylinder in place.


image


Fig. 14: Identifying Lock Components Courtesy of GENERAL MOTORS COMPANY

14. Insert the roll pin (7) into the driver (6) and install it using a 1/16 inch pin punch.

15. Insert the buffer (8) in the case (9), verify the buffer is properly seated.

16. Install the free wheel pin (11) in the sleeve (4) and clutch (5) and insert the assembly into the case (9).

17. With the lock cylinder assembly installed in the case (9), install the retainer (10) and stake the retainer in place using a small punch and hammer to peen the case material onto the exposed ends of the installed retainer (10).

18. Insert the key into the lock and function the lock to check for proper assembly and smooth operation.

LIFTING AND JACKING THE VEHICLE


NOTE: The use of a LOW PROFILE LIFT ARMS SYSTEM may be required to avoid unwanted contact with the vehicle's body and structure depending on lifting equipment used. Refer to the manufacture's recommendation for their applications of low profile lift arms system for their lifting equipment.


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Fig. 15: Lifting And Jacking Points

Courtesy of GENERAL MOTORS COMPANY


CAUTION: Lifting the vehicle improperly can damage the vehicle and result in costly repairs not covered by the warranty.


CAUTION: Perform the following steps before beginning any vehicle lifting or jacking procedure:

image Remove or secure all of the vehicle contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure.

image The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents.

image The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment manufacturer.

image Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.

image Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components.

Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle contents.


Vehicle Lifting - Frame Contact Lift


WARNING: To avoid any vehicle damage, serious personal injury or death:

image When major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

image When performing work in the engine compartment or under the vehicle, ensure that the hood is fully open, or opened to its secondary latch. When the hood is opened to the secondary latch, the vehicle will disable the remote start features from the key fob and OnStar mobile app. Failure to open the hood, or open the hood to the secondary latch while doing a repair in the engine compartment or under the vehicle can result in inadvertent vehicle starting which could result in personal injury or damage to a vehicle.


NOTE: The hoist pads must not contact the rocker panel moldings or the underbody air deflectors. Additional clearance may be required for the lifting points.


Front Lift Pads

When lifting the vehicle with a frame-contact lift, place the front lift pads in the recessed area of the rocker flange (1), as shown

Rear Lift Pads

When lifting the vehicle with a frame-contact lift, place the rear lift pads front lift pads in the recessed area of the rocker flange (2), as shown.

Vehicle Lifting - Service Jack

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Fig. 16: Service Jack Pad Locations

Courtesy of GENERAL MOTORS COMPANY


WARNING: Do not use a service jack in locations other than those specified to lift this vehicle. Lifting the vehicle with a jack in those other locations could cause the vehicle to slip off the jack and roll; this could cause injury or death.


WARNING: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack.


CAUTION: Lifting the vehicle improperly can damage the vehicle and result in costly repairs not covered by the warranty.


CAUTION: When you are jacking the vehicle at the front locations, be certain that the jack or the jack lift pad does not contact the front fascia, front fascia air dam, rocker molding, or the front fenders. If such contact occurs, vehicle damage may result. When jacking at selected front locations additional clearance may be required for the jacking points.


NOTE: It may be necessary to put ramps under the Volt's front tires in order to provide necessary clearance for certain service jacks.


Front Service Jack

When lifting the Front of the vehicle with a service jack, only lift the vehicle on the pad location (1), as shown

Rear Service Jack

When lifting the Rear of the vehicle with a service jack, only lift the vehicle on the pad location (2), as shown

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS ORDERING INFORMATION

Special Tools


The special service tools shown in this service manual that have product numbers beginning with J, BO, GE, CH, DT, EN, EL, SA, OR KM are available for worldwide distribution.

US, Canada and Caribbean only:


NOTE: For Special Service tools only - see different location below for diagnostic tools & equipment.


Bosch Automotive Service Solutions 28635 Mound Road

Warren MI

48092-3499

U.S.A

Phone: 1-800-GM-TOOLS

Monday through Friday

8:00 am - 7:00 pm Eastern Standard Time Fax: 1-800-578-7375 or 586-578-7321

gmspecialservicetools.service-solutions.com Mexico, Including Central America:

Bosch Automotive Service Solutions Mitla No. 442 Col. Vertiz Narvarte 03600 Mexico City

Mexico

Phone: +5255 2595 1630

Fax: +5255 2595 1639

Inquiries can be sent to: herramientas@service-solutions.com South America, Excluding Brazil:

Bosch Automotive Service Solutions Mitla No. 442 Col. Vertiz Narvarte 03600 Mexico City

Mexico

Phone: +5255 2595 1630

Fax: +5255 2595 1639

Inquiries can be sent to: herramientas@service-solutions.com Brazil:

Bosch Automotive Service Solutions Av. Maria Coelho de Aguiar, 573 - G10 05805-000 Sαo Paulo

Brasil

Phone: +55 11 5851-7477

Fax: +55 11 5853-7479

Inquiries can be sent to: ferramentas@service-solutions.com Korea, Thailand, Vietnam, Laos, Cambodia:

Robert Bosch Korea Ltd, Service Solution

689-17 Geumjeong-dong, Gunpo-si, Gyeonggi-do, 435-862 Korea

Phone: 82-31-457-9520

sales.korea@servicesolutions.com Fax: 82-31-427-9522

Greater China, SGM, SGMW, FAW-GM, GM OPEL China: Bosch Automotive Service Solutions China

333 Fuquan Road North IBP, Changning District

Shanghai 200335 P.R.

Phone: 86-21-22182668

sales.cn@service-solutions.com Fax: 0086 21 2218 2677

Australia:

Bosch Automotive Service Solutions Australia 1555 Centre Road,

Clayton Vic. 3168

Phone: 1300 783 031

Fax: (3) 9541 6138

Inquiries can be sent to: customerservice.au@service-solutions.com Iberica S.A.

Dealers based in Spain, Portugal and Canary Islands: Bosch Automotive Service Solutions Europe

Nave 72 (Nudo Oeste), 19004 Guadalajara, Spain

Phone: 34 949 208 337

Fax: 34 949 208 327

shop.service-solutions.com Europe GmbH

Dealers based in The Netherlands, Belgium and Luxemburg: Bosch Automotive Service Solutions Europe

Albert Tijsstraat 12, 6471 WX Kerkrade, Netherlands

Phone: 31 -45 567 8870

Fax: 31-45 567 8871

shop.service-solutions.com United Kingdom Limited Dealers based in UK:

Bosch Automotive Service Solutions Europe Ironstone Way; Brixworth, Northants, NN6 9UD, Great Britain

Phone: 44 -1327 303 400

Fax: 44 -1327 303 499

shop.service-solutions.com Italy

Dealers based in Italy:

Bosch Automotive Service Solutions Europe Via provinciale, 12, 43038 Sala Baganza-PR, Italy

Phone: 39 -521 837 508

Fax: 39 - 521 335 385

shop.service-solutions.com

Tech 2, MDI Diagnostic Tools and Accessories, Dealer Equipment


US and Canada

Dealer Equipment and Services 5775 Enterprise Drive

Warren MI, U.S.A

48092-3463

Phone: 1-800-GM-TOOLS

Monday through Friday 8:00 am - 6:00 pm EST

Fax: 1-586-578-7205

www.GMDEsolutions.net (US only) or www.des-canada.ca (Canada only)


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