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‌SPECIFICATIONS

ACCESSORIES & EQUIPMENT

Instrument Panel and Console Trim - Volt

FASTENER SPECIFICATIONS

Reusable Threaded Fastener Tightening Specifications

REPAIR INSTRUCTIONS

INSTRUMENT PANEL LOWER TRIM PANEL INSULATOR REPLACEMENT

Fig. 1: Instrument Panel Lower Trim Panel Insulator Courtesy of GENERAL MOTORS COMPANY

INSTRUMENT PANEL SWITCH TRIM PLATE REPLACEMENT

Fig. 2: Instrument Panel Switch Trim Plate Courtesy of GENERAL MOTORS COMPANY

INSTRUMENT PANEL EXTENSION REPLACEMENT

Fig. 3: Instrument Panel Extension

Courtesy of GENERAL MOTORS COMPANY

INSTRUMENT PANEL KNEE BOLSTER REPLACEMENT

Fig. 4: Instrument Panel Compartment Courtesy of GENERAL MOTORS COMPANY

INSTRUMENT PANEL TRIM PLATE APPLIQUE REPLACEMENT - RIGHT SIDE

Removal Procedure

Fig. 5: Instrument Panel Compartment Courtesy of GENERAL MOTORS COMPANY

1. Remove Instrument Panel Compartment (2)Instrument Panel Compartment Replacement

Fig. 6: Instrument Panel Outer Air Outlet Courtesy of GENERAL MOTORS COMPANY

2. Depress the three tabs on the instrument panel outer air outlet (1) from behind the instrument panel to properly release the outlet.

Fig. 7: Instrument Panel Bolt

Courtesy of GENERAL MOTORS COMPANY

3. Remove Instrument Panel Bolt (1)

4. Remove Instrument Panel Trim Plate Applique - Right Side (2)

5. Use a flat bladed plastic tool to remove.

Fig. 8: Instrument Panel Outer Air Outlet Courtesy of GENERAL MOTORS COMPANY

6. Release the plastic retaining tabs to separate the instrument panel outer air outlet (1) from the instrument panel trim plate applique (2).

7. Transfer components as necessary.

Installation Procedure

Fig. 9: Instrument Panel Outer Air Outlet Courtesy of GENERAL MOTORS COMPANY

1. Install the instrument panel outer air outlet (1) to the instrument panel trim plate applique (2).

Fig. 10: Instrument Panel Bolt

Courtesy of GENERAL MOTORS COMPANY

2. Install Instrument Panel Trim Plate Applique - Right Side (2)

CAUTION: Refer to Fastener Caution .

3. Install Instrument Panel Bolt (1) and tighten 2.5 N.m (22 lb in)

Fig. 11: Instrument Panel Compartment Courtesy of GENERAL MOTORS COMPANY

4. Install Instrument Panel Compartment (2) Instrument Panel Compartment Replacement

INSTRUMENT PANEL TRIM PLATE APPLIQUE REPLACEMENT - LEFT SIDE

Removal Procedure

Fig. 12: Instrument Panel Compartment Courtesy of GENERAL MOTORS COMPANY

1. Remove Instrument Panel Knee Bolster (2)Instrument Panel Knee Bolster Replacement

Fig. 13: Instrument Panel Switch Trim Plate Courtesy of GENERAL MOTORS COMPANY

2. Remove Instrument Panel Switch Trim Plate (2)Instrument Panel Switch Trim Plate Replacement

Fig. 14: Instrument Panel Outer Air Outlet Courtesy of GENERAL MOTORS COMPANY

3. Depress the three tabs on the instrument panel outer air outlet (1) from behind the instrument panel to properly release the outlet.

Fig. 15: Instrument Panel Bolt

Courtesy of GENERAL MOTORS COMPANY

4. Remove Instrument Panel Bolt (1)

5. Remove Instrument Panel Outer Air Outlet - Left Side (2)

6. Use a flat bladed plastic tool to remove.

Fig. 16: Instrument Panel Outer Air Outlet Courtesy of GENERAL MOTORS COMPANY

7. Release the plastic retaining tabs to separate the instrument panel outer air outlet (1) from the instrument panel trim plate applique (2).

8. Transfer components as necessary.

Installation Procedure

Fig. 17: Instrument Panel Outer Air Outlet Courtesy of GENERAL MOTORS COMPANY

1. Install the instrument panel outer air outlet (1) to the instrument panel trim plate applique (2).

Fig. 18: Instrument Panel Bolt

Courtesy of GENERAL MOTORS COMPANY

2. Install Instrument Panel Outer Air Outlet - Left Side (2)

CAUTION: Refer to Fastener Caution .

3. Install Instrument Panel Bolt (1) and tighten 2.5 N.m (22 lb in)

Fig. 19: Instrument Panel Switch Trim Plate Courtesy of GENERAL MOTORS COMPANY

4. Install Instrument Panel Switch Trim Plate (2) Instrument Panel Switch Trim Plate Replacement

Fig. 20: Instrument Panel Compartment Courtesy of GENERAL MOTORS COMPANY

5. Install Instrument Panel Knee Bolster (2)Instrument Panel Knee Bolster Replacement

FORWARD COLLISION ALERT DISPLAY BEZEL REPLACEMENT

Fig. 21: Forward Collision Alert Display Bezel Courtesy of GENERAL MOTORS COMPANY

INSTRUMENT PANEL FUSE BLOCK ACCESS HOLE COVER REPLACEMENT

Fig. 22: Instrument Panel Fuse Block Access Hole Cover Courtesy of GENERAL MOTORS COMPANY

INSTRUMENT PANEL CLUSTER TRIM PLATE REPLACEMENT

Fig. 23: Instrument Panel Cluster Trim Plate Courtesy of GENERAL MOTORS COMPANY

INSTRUMENT PANEL OUTER TRIM COVER REPLACEMENT

Fig. 24: Instrument Panel Outer Trim Cover Courtesy of GENERAL MOTORS COMPANY

INSTRUMENT PANEL LOWER CENTER TRIM PANEL REPLACEMENT (UPPER)

Fig. 25: Instrument Panel Lower Center Trim Panel (Upper) Courtesy of GENERAL MOTORS COMPANY

INSTRUMENT PANEL LOWER CENTER TRIM PANEL REPLACEMENT (LOWER)

Fig. 26: Instrument Panel Lower Center Trim Panel Courtesy of GENERAL MOTORS COMPANY

INSTRUMENT PANEL COMPARTMENT REPLACEMENT

Fig. 27: Instrument Panel Compartment Courtesy of GENERAL MOTORS COMPANY

INSTRUMENT PANEL COMPARTMENT DOOR DAMPENER REPLACEMENT

Fig. 28: Instrument Panel Compartment Door Dampener Courtesy of GENERAL MOTORS COMPANY

INSTRUMENT PANEL AIRBAG LOWER BRACKET REPLACEMENT (PASSENGER SIDE)

Fig. 29: Instrument Panel Airbag Lower Bracket (Passenger Side) Courtesy of GENERAL MOTORS COMPANY

INSTRUMENT PANEL AIRBAG LOWER BRACKET REPLACEMENT (DRIVER SIDE)

Removal Procedure

WARNING: Refer to SIR Inflator Module Handling and Storage Warning .

WARNING: Refer to SIR Warning .

1. Disable the SIR system. SIR Disabling and Enabling

Fig. 30: Instrument Panel Knee Bolster Bolt Courtesy of GENERAL MOTORS COMPANY

2. Remove Instrument Panel Knee Bolster Bolt (1)

3. Remove Instrument Panel Lower Airbag Nut (2)

Fig. 31: Instrument Panel Lower Airbag - Driver Side Courtesy of GENERAL MOTORS COMPANY

NOTE: The bracket may disassembly with the airbag.

4. Disconnect the electrical connector.

5. Remove Instrument Panel Lower Airbag - Driver Side (1)

Fig. 32: Panel Airbag Lower Bracket

Courtesy of GENERAL MOTORS COMPANY

6. Remove Instrument Panel Airbag Lower Bracket (1)

Installation Procedure

Fig. 33: Panel Airbag Lower Bracket

Courtesy of GENERAL MOTORS COMPANY

1. Install Instrument Panel Airbag Lower Bracket (1)

Fig. 34: Instrument Panel Lower Airbag - Driver Side Courtesy of GENERAL MOTORS COMPANY

2. Connect the electrical connector.

3. Install Instrument Panel Lower Airbag - Driver Side (1)

Fig. 35: Instrument Panel Knee Bolster Bolt Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution .

4. Install Instrument Panel Lower Airbag Nut (2) and tighten 9 N.m (80 lb in)

5. Install Instrument Panel Knee Bolster Bolt (1) and tighten 2.5 N.m (22 lb in)

6. Enable the SIR System. SIR Disabling and Enabling

INSTRUMENT PANEL ASSEMBLY REPLACEMENT

Removal Procedure

1. Disable the SIR system. SIR Disabling and Enabling

Fig. 36: Steering Column

Courtesy of GENERAL MOTORS COMPANY

2. Remove Steering Column Replacement (1)

Fig. 37: Front Floor Console

Courtesy of GENERAL MOTORS COMPANY

3. Remove Front Floor Console Replacement(3)

Fig. 38: Instrument Panel Lower Center Trim Panel Courtesy of GENERAL MOTORS COMPANY

4. Remove Instrument Panel Lower Center Trim Panel Replacement (Upper)Instrument Panel Lower Center Trim Panel Replacement (Lower)(1)

Fig. 39: Instrument Cluster

Courtesy of GENERAL MOTORS COMPANY

5. Remove Instrument Cluster Replacement (2)

Fig. 40: Radio Front Speaker

Courtesy of GENERAL MOTORS COMPANY

6. Remove Radio Front Speaker Replacement (2)

Fig. 41: Radio Front Center Speaker

Courtesy of GENERAL MOTORS COMPANY

7. Remove Radio Front Center Speaker Replacement (2)

Fig. 42: Human Machine Interface Control Module Courtesy of GENERAL MOTORS COMPANY

8. Remove Human Machine Interface Control Module Replacement (1)

Fig. 43: Heater and Air Conditioning Remote Control Courtesy of GENERAL MOTORS COMPANY

9. Remove Heater and Air Conditioning Remote Control Replacement (1)

Fig. 44: Forward Collision Alert Display Courtesy of GENERAL MOTORS COMPANY

10. Remove Forward Collision Alert Display Replacement (2)

Fig. 45: Instrument Panel Bolt

Courtesy of GENERAL MOTORS COMPANY

11. Remove Instrument Panel Bolt (1)

Fig. 46: Instrument Panel Bolt

Courtesy of GENERAL MOTORS COMPANY

12. Remove Instrument Panel Bolt (1)

Fig. 47: Instrument Panel Bolt

Courtesy of GENERAL MOTORS COMPANY

13. Remove Instrument Panel Bolt (1)

Fig. 48: Instrument Panel Airbag Bolt Courtesy of GENERAL MOTORS COMPANY

14. Remove Instrument Panel Airbag Bolt (1)

15. Disconnect the electrical connector.

Fig. 49: Instrument Panel Carrier Assembly Courtesy of GENERAL MOTORS COMPANY

16. Note the location and routing of the instrument panel wiring harness prior to removal to ensure proper installation.

17. Disconnect the wiring harness from the instrument panel carrier.

18. With the aid of an assistant, remove the instrument panel carrier assembly from the vehicle.(1)

19. Transfer components as necessary.

Installation Procedure

Fig. 50: Instrument Panel Carrier Assembly Courtesy of GENERAL MOTORS COMPANY

1. With the aid of an assistant, position the instrument carrier in the vehicle.(1)

2. Reposition the instrument panel wiring harness into the vehicle position as was noted in the removal and connect the fasteners securing the instrument panel wiring harness to the instrument carrier.

Fig. 51: Instrument Panel Airbag Bolt Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution .

3. Install Instrument Panel Airbag Bolt (1) and tighten 9 N.m (7 lb ft)

4. Connect the electrical connector.

Fig. 52: Instrument Panel Bolt

Courtesy of GENERAL MOTORS COMPANY

5. Install Instrument Panel Bolt (1) and tighten 2.5 N.m (22 lb in)

Fig. 53: Instrument Panel Bolt

Courtesy of GENERAL MOTORS COMPANY

6. Install Instrument Panel Bolt (1) and tighten 2.5 N.m (22 lb in)

Fig. 54: Instrument Panel Bolt

Courtesy of GENERAL MOTORS COMPANY

7. Install Instrument Panel Bolt (1) and tighten 2.5 N.m (22 lb in)

Fig. 55: Forward Collision Alert Display Courtesy of GENERAL MOTORS COMPANY

8. Install Forward Collision Alert Display Replacement (2)

Fig. 56: Heater and Air Conditioning Remote Control Courtesy of GENERAL MOTORS COMPANY

9. Install Heater and Air Conditioning Remote Control Replacement (1)

Fig. 57: Human Machine Interface Control Module Courtesy of GENERAL MOTORS COMPANY

10. Install Human Machine Interface Control Module Replacement (1)

Fig. 58: Radio Front Speaker

Courtesy of GENERAL MOTORS COMPANY

11. Install Radio Front Speaker Replacement (2)

Fig. 59: Radio Front Center Speaker

Courtesy of GENERAL MOTORS COMPANY

12. Install Radio Front Center Speaker Replacement (2)

Fig. 60: Instrument Cluster

Courtesy of GENERAL MOTORS COMPANY

13. Install Instrument Cluster Replacement (2)

Fig. 61: Instrument Panel Lower Center Trim Panel Courtesy of GENERAL MOTORS COMPANY

14. Install Instrument Panel Lower Center Trim Panel Replacement (Upper)Instrument Panel Lower Center Trim Panel Replacement (Lower) (1)

Fig. 62: Front Floor Console

Courtesy of GENERAL MOTORS COMPANY

15. Install Front Floor Console Replacement (3)

Fig. 63: Steering Column

Courtesy of GENERAL MOTORS COMPANY

16. Install Steering Column Replacement (1)

17. Enable the SIR System. SIR Disabling and Enabling

INSTRUMENT PANEL TIE BAR REPLACEMENT

Removal Procedure

1. Remove Instrument Panel Assembly Replacement

Fig. 64: Instrument Panel Lower Trim Panel Insulator Courtesy of GENERAL MOTORS COMPANY

2. Remove Instrument Panel Lower Trim Panel Insulator Replacement (3)

Fig. 65: Instrument Panel Lower Airbag - Passenger Side Courtesy of GENERAL MOTORS COMPANY

3. Remove Instrument Panel Lower Airbag Replacement - Passenger Side (2)

Fig. 66: Front Side Door Sill Trim Plate Courtesy of GENERAL MOTORS COMPANY

4. Remove Front Side Door Sill Trim Plate Replacement (1)

Fig. 67: Communication Interface Module Bracket Courtesy of GENERAL MOTORS COMPANY

5. Remove Communication Interface Module Bracket Replacement (2)

Fig. 68: Front Side Door

Courtesy of GENERAL MOTORS COMPANY

6. Remove Front Side Door Replacement (4)

Fig. 69: Windshield Wiper System Module Courtesy of GENERAL MOTORS COMPANY

7. Remove Windshield Wiper System Module Replacement (2)

Fig. 70: Instrument Panel Upper Bolt

Courtesy of GENERAL MOTORS COMPANY

8. Remove Instrument Panel Upper Bolt (1)

Fig. 71: Body Hinge Pillar Outer Panel Hole Plug And Bolt Courtesy of GENERAL MOTORS COMPANY

9. Remove Body Hinge Pillar Outer Panel Hole Plug (1)

10. Remove Instrument Panel Bolt (2)

Fig. 72: Body Hinge Pillar Outer Panel Hole Plug And Bolt Courtesy of GENERAL MOTORS COMPANY

11. Remove Body Hinge Pillar Outer Panel Hole Plug (1)

12. Remove Instrument Panel Bolt (2)

Fig. 73: Data Link Connector And Bolt Courtesy of GENERAL MOTORS COMPANY

13. Remove Data Link Connector Bolt (1)

14. Reposition away Data Link Connector (2)

Fig. 74: Instrument Panel Wiring Harness Junction Block Courtesy of GENERAL MOTORS COMPANY

15. Use a suitable tool to release the Instrument Panel Wiring Harness Junction Block (1) from the Instrument Panel Tie Bar and position out of the way.

Fig. 75: Wiring Harness Ground Nut

Courtesy of GENERAL MOTORS COMPANY

16. Remove Wiring Harness Ground Nut (1)

Fig. 76: Brake Pedal Bolt

Courtesy of GENERAL MOTORS COMPANY

17. Remove Brake Pedal Bolt (1)

Fig. 77: Heater and Air Conditioning Evaporator and Blower Module Nut Courtesy of GENERAL MOTORS COMPANY

18. Remove Heater and Air Conditioning Evaporator and Blower Module Nut (1)

Fig. 78: Heater and Air Conditioning Evaporator Module Bolt Courtesy of GENERAL MOTORS COMPANY

19. Remove Heater and Air Conditioning Evaporator Module Bolt (1)

Fig. 79: Instrument Panel Tie Bar Brace Bolt Courtesy of GENERAL MOTORS COMPANY

20. Remove Instrument Panel Tie Bar Brace Bolt (1)

Fig. 80: Wiring Harness Ground Nut

Courtesy of GENERAL MOTORS COMPANY

21. Remove Wiring Harness Ground Nut (1)

Fig. 81: Heater and Air Conditioning Evaporator and Blower Module Bolt Courtesy of GENERAL MOTORS COMPANY

22. Remove Heater and Air Conditioning Evaporator and Blower Module Bolt (1)

Fig. 82: Instrument Panel Tie Bar Reinforcement Bolt Courtesy of GENERAL MOTORS COMPANY

23. Remove Instrument Panel Tie Bar Reinforcement Bolt (1)

24. Note the location and routing of the instrument panel wiring harness prior to removal to ensure proper installation.

25. Support the HVAC module in order to prevent damage.

26. With the aid of an assistant, remove the instrument panel tie bar assembly from the vehicle.(2)

27. Transfer components as necessary.

Installation Procedure

1. With the aid of an assistant, position the instrument panel tie bar assembly into the vehicle.

2. Install the instrument panel wiring harness assembly to the position noted in the removal procedure.

Fig. 83: Instrument Panel Tie Bar Reinforcement Bolt Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution .

3. Install Instrument Panel Tie Bar (2)

4. Install Instrument Panel Tie Bar Reinforcement Bolt (1) and tighten 22 N.m (16 lb ft)

Fig. 84: Heater and Air Conditioning Evaporator and Blower Module Bolt Courtesy of GENERAL MOTORS COMPANY

5. Install Heater and Air Conditioning Evaporator and Blower Module Bolt (1) and tighten 5 N.m (44 lb in)

Fig. 85: Wiring Harness Ground Nut

Courtesy of GENERAL MOTORS COMPANY

6. Install Wiring Harness Ground Nut (1) and tighten 2.5 N.m (22 lb in)

Fig. 86: Instrument Panel Tie Bar Brace Bolt Courtesy of GENERAL MOTORS COMPANY

7. Install Instrument Panel Tie Bar Brace Bolt (1) and tighten 22 N.m (16 lb ft)

Fig. 87: Heater and Air Conditioning Evaporator Module Bolt Courtesy of GENERAL MOTORS COMPANY

8. Install Heater and Air Conditioning Evaporator Module Bolt (1) and tighten 5 N.m (44 lb in)

Fig. 88: Heater and Air Conditioning Evaporator and Blower Module Nut Courtesy of GENERAL MOTORS COMPANY

9. Install Heater and Air Conditioning Evaporator and Blower Module Nut (1) and tighten 5 N.m (44 lb in)

Fig. 89: Brake Pedal Bolt

Courtesy of GENERAL MOTORS COMPANY

10. Install Brake Pedal Bolt (1) and tighten 22 N.m (16 lb ft)

Fig. 90: Wiring Harness Ground Nut

Courtesy of GENERAL MOTORS COMPANY

11. Install Wiring Harness Ground Nut (1) and tighten 2.5 N.m (22 lb in)

Fig. 91: Instrument Panel Wiring Harness Junction Block Courtesy of GENERAL MOTORS COMPANY

12. Install the Instrument Panel Wiring Harness Junction Block (1) to the Instrument Panel Tie Bar.

Fig. 92: Data Link Connector And Bolt Courtesy of GENERAL MOTORS COMPANY

13. Install Data Link Connector (2)

14. Install Data Link Connector Bolt (1) and tighten 2.5 N.m (22 lb in)

Fig. 93: Body Hinge Pillar Outer Panel Hole Plug And Bolt Courtesy of GENERAL MOTORS COMPANY

15. Install Instrument Panel Bolt (2) and tighten 22 N.m (16 lb ft)

16. Install Body Hinge Pillar Outer Panel Hole Plug (1)

Fig. 94: Body Hinge Pillar Outer Panel Hole Plug And Bolt Courtesy of GENERAL MOTORS COMPANY

17. Install Instrument Panel Bolt (2) and tighten 22 N.m (16 lb ft)

18. Install Body Hinge Pillar Outer Panel Hole Plug (1)

Fig. 95: Instrument Panel Upper Bolt

Courtesy of GENERAL MOTORS COMPANY

19. Install Instrument Panel Upper Bolt (1) and tighten 22 N.m (16 lb ft)

Fig. 96: Windshield Wiper System Module Courtesy of GENERAL MOTORS COMPANY

20. Install Windshield Wiper System Module Replacement (2)

Fig. 97: Front Side Door

Courtesy of GENERAL MOTORS COMPANY

21. Install Front Side Door Replacement (4)

Fig. 98: Communication Interface Module Bracket Courtesy of GENERAL MOTORS COMPANY

22. Install Communication Interface Module Bracket Replacement (2)

Fig. 99: Front Side Door Sill Trim Plate Courtesy of GENERAL MOTORS COMPANY

23. Install Front Side Door Sill Trim Plate Replacement (1)

Fig. 100: Instrument Panel Lower Airbag - Passenger Side Courtesy of GENERAL MOTORS COMPANY

24. Install Instrument Panel Lower Airbag Replacement - Passenger Side (2)

Fig. 101: Instrument Panel Lower Trim Panel Insulator Courtesy of GENERAL MOTORS COMPANY

25. Install Instrument Panel Lower Trim Panel Insulator Replacement (3)

26. Install Instrument Panel Assembly Replacement

INSTRUMENT PANEL TIE BAR BRACE REPLACEMENT

Fig. 102: Instrument Panel Tie Bar Brace Courtesy of GENERAL MOTORS COMPANY

WIRE TO WIRE REPAIR - INSTRUMENT PANEL AND CONSOLE

Special Tools

EL-38125-10 Splice Sleeve Crimping Tool (non GMNA)

J-38125-5A Ultra Torch Special Tool

J-38125-8 Splice Sleeve Crimping Tool (GMNA)

For equivalent regional tools, refer to Special Tools .

WARNING: In order to reduce the risk of personal injury, loss of high voltage isolation to ground and higher system impedance, do not attempt to repair any HV wiring, connector, or terminal that is damaged. High voltage coaxial type cables are not repairable. Never attempt to repair a coaxial type cable. The entire cable/harness or component must be replaced. In order to maintain system integrity and personal safety, never attempt to repair any high voltage wiring,

cables, or terminals. Performing this procedure on high voltage circuits may result in serious injury or death.

NOTE: If the wiring harness internal to the transmission is damaged, the wiring harness must be replaced. The use of splice sleeves in an attempt to repair the internal transmission wires, connectors, or terminals could result in performance issues.

NOTE: Do not splice wires in Door Harness Grommets.

NOTE: The DuraSeal splice sleeves have the following 2 critical features:

A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside.

A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits.

Use only DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except high voltage and specialty cables. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing.

Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves.

Splice Sleeve Selection

NOTE: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.

1. Open the harness by removing any tape:

Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage.

Use the DuraSeal splice sleeves on all types of insulation except Tefzel and coaxial.

Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together.

2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.

Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness

branches, or connectors.

3. Strip the insulation:

When adding a length of wire to the existing harness, use the same size wire as the original wire. Perform one of the following items in order to find the correct wire size:

Find the wire on the schematic and convert to regional wiring gauge size.

If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation.

Strip approximately 5.0 mm (0.20 in) of insulation from each wire to be spliced.

Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section.

4. For high temperature wiring, slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure.

5. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests.

Fig. 103: Splice Sleeve Crimping Tool With 4 Crimp Nests

Courtesy of GENERAL MOTORS COMPANY

6. The EL-38125-10 splice sleeve crimping tool has four crimp nests. The largest crimp nest (4) is used for crimping 10 and 12 gauge wires. The second largest crimp nest (3) is used for crimping 14 and 16 gauge wires. The third largest crimp nest (2) is used for crimping 18 and 20 gauge wires. The smallest crimp nest (1) is used for crimping 22 to 26 gauge wires. The crimp nests are referenced in the table (farther above) under the crimp tool nest color.

Fig. 104: Splice Sleeve Crimping Tool With 3 Crimp Nests Courtesy of GENERAL MOTORS COMPANY

7. The J-38125-8 splice sleeve crimping tool has three crimp nests. The largest crimp nest (3) is used for crimping 10 and 12 gauge wires. The second largest crimp nest (2) is used for crimping 14 and 16 gauge wires. The smallest crimp nest (1) is used for crimping 18 to 20 gauge wires. The crimp nests are referenced in the table (farther above) under the crimp tool nest color.

8. Use the splice sleeve crimp tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. For the four crimp nest tool, use the three largest crimp nests to crimp the splice sleeves. For the three crimp nest tool, use all three crimp nests to crimp the splice sleeves. Use the four and three crimp tool diagrams (above) and the table (farther above) to match the splice sleeve with the correct crimp nest. The crimp tool diagram callout numbers match the numbers in the table (under

crimp tool nest color).

Fig. 105: Identifying Duraseal Splice Sleeve Courtesy of GENERAL MOTORS COMPANY

9. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.

Fig. 106: Crimped Duraseal Splice Sleeve Courtesy of GENERAL MOTORS COMPANY

10. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. Refer to Folded-Over Wire Repair for splicing wires of 0.35 mm or less (22, 24, 26 gauge sizes) and for splicing wires of different gauges.

11. Tightly close the handles of the crimp tool until the crimper handles open when released.

The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 6 for the opposite end of the splice.

Fig. 107: Crimped Duraseal Splice Sleeve Courtesy of GENERAL MOTORS COMPANY

12. Using the heat torch, apply heat to the crimped area of the barrel.

13. Start in the middle and gradually move the heat barrel to the open ends of the tubing: The tubing will shrink completely as the heat is moved along the insulation.

A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

Weatherpack™ Wiring Repair

NOTE: Some replacement pigtail connectors may be delivered without the terminated leads installed into the connector. For Weatherpack™ connectors, all terminated leads included in the package should to be installed into the connector. If the connector end view shows that a terminal is not occupied, the extra terminated lead(s) need to be installed and the end(s) sealed using a DuraSeal splice sleeve and taped back into the harness.

1. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. Refer to Folded-Over Wire Repair for splicing wires of 0.35 mm or less (22, 24, 26 gauge sizes) and for splicing wires of different gauges.

Fig. 108: Tightly Close Handles Of Crimp Tool Courtesy of GENERAL MOTORS COMPANY

2. Tightly close the handles of the crimp tool until the crimper handles open when released.

The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Holding the DuraSEAL with one hand gently tug on the wire to ensure it is crimped in the DuraSeal.

3. Using the heat torch, apply heat to the crimped area of the barrel.

Fig. 109: Heat To Crimped Area Of Barrel Courtesy of GENERAL MOTORS COMPANY

4. Start in the middle and gradually move the heat barrel to the open ends of the tubing: The tubing will shrink completely as the heat is moved along the insulation.

A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

Fig. 110: Taping Extra Terminated Leads Back Into Harness Courtesy of GENERAL MOTORS COMPANY

5. Tape the extra terminated lead(s) back into the harness.

High Temperature Wiring Repairs

Use the following procedures to perform high temperature wiring repairs:

1. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve.

2. Using the heat torch, apply heat to the high temperature heat shrink tubing.

3. Gradually move the heat from the center to the open end of the tubing:

The tubing will shrink completely as the heat is moved along the insulation.

A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

4. Replace any reflective tape and clips that may have been removed during the repair.

CONNECTOR RECONNECTION - INSTRUMENT PANEL AND CONSOLE

Special Tools

EL-35616 Terminal Test Probe Kit

For equivalent regional tools, refer to Special Tools .

When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition.

Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items:

Loose, corroded, or painted terminal stud/fastener Wiring broken inside the insulation

Poor connection between the male and female terminal at a connector A terminal not seated all the way into the connector body

Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc.

Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits.

Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle.

Wiring that comes in contact with hot or exhaust components

Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern.

Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions.

Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation.

Testing for Terminal Fretting

Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface.

To correct a fretting condition disconnect the suspect connector and add dielectric grease / lubricant (Nyogel

760G or equivalent, meeting GM specification 9986087) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion.

Testing for Proper Terminal Contact

It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation.

Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.

Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the EL-35616 kit when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit.

Testing for Proper Terminal Contact in Bussed Electrical Centers

It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center. Use the EL-35616 kit to test for proper terminal contact. Failure to use the EL-35616 kit can result in improper diagnosis of the bussed electrical center.

Follow the procedure below in order to test terminal contact:

1. Separate the connector halves.

2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body.

3. Using an equivalent male terminal/terminated lead, verify that the retention force is significantly different between a known good terminal and the suspect terminal. Replace the female terminal in question.

Flat Wire Connectors

There are no serviceable parts for flat wire connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact:

1. Remove the component in question.

2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well.

3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation.

4. Insert the appropriate adapter into the flat wire harness connector in order to test the circuit in question.

Control Module/Component Voltage and Grounds

Poor voltage or ground connections can cause widely varying symptoms.

Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current.

Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing

, and Power Distribution Schematics .

Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested.

Inspect grounds for clean and tight connections at the grounding point (screw or stud). Inspect the connections at the component and in splice packs, where applicable. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing , and Ground Distribution Schematics .

Temperature Sensitivity

An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot.

Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable.

If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures

Underhood/engine generated heat

Circuit generated heat due to a poor connection, or high electrical load Higher than normal load conditions, towing, etc.

If the intermittent is related to cold, review the data for the following:

Low ambient temperatures - In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion.

The condition only occurs on a cold start.

The condition goes away when the vehicle warms up.

Information from the customer may help to determine if the trouble follows a pattern that is temperature related.

If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition.

Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required.

Electromagnetic Interference and Electrical Noise

Some electrical components/circuits are sensitive to electromagnetic interference or other types of electrical noise. Inspect for the following conditions:

A mis-routed harness that is too close to high voltage/high current devices such as secondary ignition

components, motors, generator etc. - These components may induce electrical noise on a circuit that could interfere with normal circuit operation.

Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch - These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating.

Installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc. - These accessories may create interference in other circuits while operating and the interference would disappear when the accessory is not operating. Refer to Checking Aftermarket Accessories .

Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode.

The generator may be allowing AC noise into the electrical system.

Incorrect Control Module

There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed.

A control module from another vehicle is installed.

Revised software/calibration files have been released for this vehicle.

NOTE: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern.

Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming.

FRONT FLOOR CONSOLE COMPARTMENT DIVIDER REPLACEMENT

Fig. 111: Front Floor Console Compartment Divider Courtesy of GENERAL MOTORS COMPANY

FRONT FLOOR CONSOLE FRONT COMPARTMENT LINER REPLACEMENT

Fig. 112: Front Floor Console Front Compartment Liner Courtesy of GENERAL MOTORS COMPANY

FRONT FLOOR CONSOLE CUP HOLDER LINER REPLACEMENT

Fig. 113: Front Floor Console Cup Holder Liner Courtesy of GENERAL MOTORS COMPANY

FRONT FLOOR CONSOLE REAR CUP HOLDER REPLACEMENT

Fig. 114: Front Floor Console Rear Cup Holder Courtesy of GENERAL MOTORS COMPANY

FRONT FLOOR CONSOLE COMPARTMENT LINER REPLACEMENT

Fig. 115: Front Floor Console Compartment Liner Courtesy of GENERAL MOTORS COMPANY

FRONT FLOOR CONSOLE CENTER COMPARTMENT LINER REPLACEMENT

Fig. 116: Front Floor Console Center Compartment Liner Courtesy of GENERAL MOTORS COMPANY

FRONT FLOOR CONSOLE ACCESSORY TRIM PLATE REPLACEMENT

Fig. 117: Front Floor Console Accessory Trim Plate Courtesy of GENERAL MOTORS COMPANY

FRONT FLOOR CONSOLE EXTENSION PANEL REPLACEMENT - RIGHT SIDE

Fig. 118: Front Floor Console Extension Panel - Right Side Courtesy of GENERAL MOTORS COMPANY

FRONT FLOOR CONSOLE EXTENSION PANEL REPLACEMENT - LEFT SIDE

Fig. 119: Front Floor Console Extension Panel - Left Side Courtesy of GENERAL MOTORS COMPANY

FRONT FLOOR CONSOLE REPLACEMENT

Fig. 120: Front Floor Console

Courtesy of GENERAL MOTORS COMPANY

FRONT FLOOR LOWER CONSOLE REPLACEMENT

Fig. 121: Front Floor Lower Console

Courtesy of GENERAL MOTORS COMPANY

FRONT FLOOR REAR CONSOLE SIDE TRIM PANEL REPLACEMENT - LEFT SIDE

Fig. 122: Front Floor Rear Console Side Trim Panel - Left Side Courtesy of GENERAL MOTORS COMPANY

FRONT FLOOR REAR CONSOLE SIDE TRIM PANEL REPLACEMENT - RIGHT SIDE

Fig. 123: Front Floor Rear Console Side Trim Panel - Right Side Courtesy of GENERAL MOTORS COMPANY

FRONT FLOOR CONSOLE ARMREST LATCH REPLACEMENT

Fig. 124: Front Floor Console Armrest Latch Courtesy of GENERAL MOTORS COMPANY

FRONT FLOOR CONSOLE ARMREST REPLACEMENT

Removal Procedure

1. Remove Front Floor Console Rear Cup Holder Replacement

Fig. 125: Front Floor Console Armrest Hinge Washer Courtesy of GENERAL MOTORS COMPANY

2. Use a suitable tool to release the Front Floor Console Armrest Clip Hinge Retention (1) from the Hinge Pin.

3. Remove Front Floor Console Armrest Hinge Washer (2)

4. Position the front seat as needed to access the Front Floor Console Armrest Hinge Pin.

Fig. 126: Front Floor Rear Console Side Trim Panel Courtesy of GENERAL MOTORS COMPANY

5. Release the lower clips of the front floor rear console side trim panel (1) to allow the door hinge pin to be to removed. Careful not to damage the tabs on the top of the panel and the forward hidden fastener.

Fig. 127: Front Floor Console Compartment Door Hinge Pin Courtesy of GENERAL MOTORS COMPANY

6. Remove Front Floor Console Compartment Door Hinge Pin (1) @Armrest Assembly

Fig. 128: Front Floor Console Armrest Hinge Courtesy of GENERAL MOTORS COMPANY

7. Use a suitable tool to release the ends of the Front Floor Console Armrest Hinge (1) from the Hinge Arm.

Fig. 129: Front Floor Console Armrest Courtesy of GENERAL MOTORS COMPANY

8. Remove Front Floor Console Armrest (1) @Front Floor Console Assembly

Installation Procedure

Fig. 130: Front Floor Console Armrest Courtesy of GENERAL MOTORS COMPANY

1. Install Front Floor Console Armrest (1) @Front Floor Console Assembly

Fig. 131: Front Floor Console Armrest Hinge Courtesy of GENERAL MOTORS COMPANY

2. Attach the ends of the Front Floor Console Armrest Hinge (1) to the Hinge Arm.

Fig. 132: Front Floor Console Compartment Door Hinge Pin Courtesy of GENERAL MOTORS COMPANY

3. Install Front Floor Console Compartment Door Hinge Pin (1) @ Armrest Assembly

Fig. 133: Front Floor Rear Console Side Trim Panel Courtesy of GENERAL MOTORS COMPANY

4. Install Front Floor Rear Console Side Trim Panel - Right Side (1)

Fig. 134: Front Floor Console Armrest Hinge Washer Courtesy of GENERAL MOTORS COMPANY

5. Install Front Floor Console Armrest Hinge Washer (2)

6. Install Front Floor Console Armrest Clip Hinge Retention (1) @Hinge Pin

7. Install Front Floor Console Rear Cup Holder Replacement

FRONT FLOOR CONSOLE ARMREST HINGE REPLACEMENT

Removal Procedure

1. Remove Front Floor Console Rear Cup Holder Replacement

Fig. 135: Front Floor Console Armrest Hinge Washer Courtesy of GENERAL MOTORS COMPANY

2. Use a suitable tool to release the Front Floor Console Armrest Clip Hinge Retention (1) from the Hinge Pin.

3. Remove Front Floor Console Armrest Hinge Washer (2)

4. Position the front seat as needed to access the Front Floor Console Armrest Hinge Pin.

Fig. 136: Front Floor Rear Console Side Trim Panel Courtesy of GENERAL MOTORS COMPANY

5. Release the lower clips of the front floor rear console side trim panel (1) to allow the door hinge pin to be to removed. Careful not to damage the tabs on the top of the panel and the forward hidden fastener.

Fig. 137: Front Floor Console Compartment Door Hinge Pin Courtesy of GENERAL MOTORS COMPANY

6. Remove Front Floor Console Compartment Door Hinge Pin (1) @Armrest Assembly

Fig. 138: Front Floor Console Armrest Hinge Courtesy of GENERAL MOTORS COMPANY

7. Use a suitable tool to release the ends of the Front Floor Console Armrest Hinge (1) from the Hinge Arm.

Fig. 139: Front Floor Console Armrest Courtesy of GENERAL MOTORS COMPANY

8. Remove Front Floor Console Armrest (1) @Front Floor Console Assembly

Fig. 140: Front Floor Console Armrest Hinge Courtesy of GENERAL MOTORS COMPANY

9. Remove Front Floor Console Armrest Hinge (1) @ Hinge Arm

Installation Procedure

Fig. 141: Front Floor Console Armrest Hinge Courtesy of GENERAL MOTORS COMPANY

1. Install Front Floor Console Armrest Hinge (1) @ Hinge Arm

Fig. 142: Front Floor Console Armrest Courtesy of GENERAL MOTORS COMPANY

2. Install Front Floor Console Armrest (1) @Front Floor Console Assembly

Fig. 143: Front Floor Console Armrest Hinge Courtesy of GENERAL MOTORS COMPANY

3. Attach the ends of the Front Floor Console Armrest Hinge (1) to the Hinge Arm.

Fig. 144: Front Floor Console Compartment Door Hinge Pin Courtesy of GENERAL MOTORS COMPANY

4. Install Front Floor Console Compartment Door Hinge Pin (1) @ Armrest Assembly

Fig. 145: Front Floor Rear Console Side Trim Panel Courtesy of GENERAL MOTORS COMPANY

5. Install Front Floor Rear Console Side Trim Panel - Right Side (1)

Fig. 146: Front Floor Console Armrest Hinge Washer Courtesy of GENERAL MOTORS COMPANY

6. Install Front Floor Console Armrest Hinge Washer (2)

7. Install Front Floor Console Armrest Clip Hinge Retention (1) @Hinge Pin

8. Install Front Floor Console Rear Cup Holder Replacement

FRONT FLOOR CONSOLE APPLIQUE REPLACEMENT - RIGHT SIDE

Fig. 147: Front Floor Console Applique - Right Side Courtesy of GENERAL MOTORS COMPANY

FRONT FLOOR CONSOLE APPLIQUE REPLACEMENT - LEFT SIDE

Fig. 148: Front Floor Console Applique - Left Side Courtesy of GENERAL MOTORS COMPANY

ROOF CONSOLE REPLACEMENT

Fig. 149: Roof Console

Courtesy of GENERAL MOTORS COMPANY

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