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Preface Preface P-1

Preface

CAUTION

Caution: In order to reduce the chance of personal injury and/or property damage, carefully

observe the instructions that follow:

The service manuals of General Motors Corporation are intended for use by professional,

qualified technicians. Attempting repairs or service without the appropriate training, tools,

and equipment could cause injury to you or others. This could also damage the vehicle, or

cause the vehicle to operate improperly.

Proper vehicle service and repair are important to the safety of the service technician and to

the safe, reliable operation of all motor vehicles. If you need to replace a part, use the same

part number or an equivalent part. Do not use a replacement part of lesser quality.

The service procedures we recommend and describe in this service manual are effective

methods of performing service and repair. Some of the procedures require the use of tools

that are designed for specific purposes.

Accordingly, any person who intends to use a replacement part, a service procedure, or a

tool that is not recommended by General Motors, must first establish that there is no

jeopardy to personal safety or the safe operation of the vehicle.

This manual contains various “Cautions” and “Notices” that you must observe carefully in

order to reduce the risk of personal injury during service or repair. Improper service or

repair may damage the vehicle or render the vehicle unsafe. These “Cautions” and “Notices”

are not exhaustive. General Motors can not possibly warn of all the potentially hazardous

consequences of your failure to follow these instructions.

This manual covers service procedures to vehicles that are equipped with a Supplemental

Inflatable Restraint (SIR). Refer to the “Cautions” in Cautions and Notices and in Restraints.

Refer to SIR component and wiring location views in Restraints before performing a service

on or around SIR components or wiring. Failure to follow these “Cautions” could cause air

bag deployment, personal injury, or otherwise unneeded SIR repairs.

In order to help avoid accidental air bag deployment and personal injury, whenever you

service a vehicle that requires repair of the SIR and another vehicle system, we recommend

that you first repair the SIR, then go on to the other system.

Summary of content (314 pages)

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Preface Preface P-1 Preface CAUTION Caution: In order to reduce the chance of personal injury and/or property damage, carefully observe the instructions that follow: The service manuals of General Motors Corporation are intended for use by professional, qualified technicians. Attempting repairs or service without the appropriate training, tools, and equipment could cause injury to you or others. This could also damage the vehicle, or cause the vehicle to operate improperly.
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Preface P-2 Preface 2006 General Motors LSSV/EMP Trucks Service Manual Supplement Volume 1 This manual provides information on the diagnosis, the service procedures, the adjustments, and the specifications for the 2006 General Motors LSSV/EMP Trucks. Information on transmission unit repair (overhaul) can be found in the 2006 Transmission/Transaxle/Unit Repair Manual (TURM), available separately.
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Preface Preface P-3 BLANK
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Cautions and Notices P-4 Preface Cautions and Notices Fastener Notice Battery Disconnect Caution Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
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Table of Contents Table of Contents 1 Table of Contents Preface General Information General Information.................................................0-3 Maintenance and Lubrication ..................................0-7 Steering Power Steering System...........................................2-3 Suspension Front Suspension ....................................................3-3 Rear Suspension.....................................................3-9 Tires and Wheels ....................................
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2 Table of Contents 2 Table of Contents BLANK 2006 LSSV Service Manual Supplement
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General Information Table of Contents 0-1 Section 0 General Information General Information..................................0-3 Introduction ..........................................................0-3 Vehicle Identification...........................................0-3 RPO Code List....................................................0-4 LSSV Equipment Options ...................................0-5 LSSV Labels .......................................................0-5 Maintenance and Lubrication .....
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0-2 Table of Contents General Information BLANK 2006 LSSV Service Manual Supplement
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General Information General Information General Information 0-3 Cargo/Troop Carrier Base Introduction Vehicle Identification The 2006 LSSV series pickup models derive from standard commercial vehicles. The pickup is a 2500HD, or “9200 lb GVW” based pickup. The pickup vehicles have rugged designs intended for all types of roads or infrequent off-road travel. They can ford water obstacles for three minutes without stalling at depths of 51 cm (20 in) at 8 kph (5 mph).
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0-4 General Information General Information RPO Code List RPO Table RPO Description The production/process codes provide the description of the LSSV Option.
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General Information General Information 0-5 LSSV Equipment Options LSSV Labels 2006 Light Service Support Vehicle – LSSV Specifications/Options Your vehicle may have some or all of the following labels. Your vehicle may be equipped with any combination of the following options.
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0-6 General Information 24V Battery Caution Label The 24V battery caution label is placed on top of the radiator support near the 24V battery. This battery is on the left side of the engine compartment. Vehicle Identification Plate The vehicle identification plate is located on the left front inner door panel under the shipping data plate. This plate includes the identification number, contract number and vehicle variant.
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General Information Maintenance and Lubrication 0-7 Fluid and Lubricant Recommendations Maintenance and Lubrication The Recommended Fluids and Lubricants information will be found in the Owners Manual and Owners Manual Supplement. Refer to the Maintenance Schedule subsection of the Owners Manual. Specifications Capacities – Approximate Fluid See Fluid and Lubricant Recommendations for more information. All capacities are approximate.
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0-8 Maintenance and Lubrication General Information Tire Pressure Monitoring System Settings (EMP Only) Tire Pressure and Slope Terrain Cold Inflation Pressure Slope Highway * Front Axle 3.10 Bar (45 PSI) 55 Highway * Rear Axle 4.48 Bar (65 PSI) 75 Highway ** 2.76 Bar (40 PSI) 51 Cross Country ** 1.60 Bar (23 PSI) 34 Mud, Sand, Snow ** 1.24 Bar (18 PSI) 29 Tire Pressure and Slope Terrain Deviation Pressure Alert *** Low Pressure Warning Highway * Front Axle 0.34 Bar (±5 PSI) 2.
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Steering Table of Contents 2-1 Section 2 Steering Power Steering System............................ 2-3 Specifications .......................................................2-3 Repair Instructions...............................................2-4 Power Steering Pump Heat Shield Replacement.......................................................
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2-2 Power Steering Steering BLANK 2006 LSSV Service Manual Supplement
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Steering Power Steering System 2-3 Power Steering System Specifications Fastener Tightening Specifications Specification Application Power Steering Pump Heat Shield Bolts Metric English 8 N•m 71 lb in 2006 LSSV Service Manual Supplement
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2-4 Power Steering System Steering Repair Instructions Power Steering Pump Heat Shield Replacement Removal Procedure Caution: Refer to Vehicle Lifting Caution in Cautions and Notices. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in 2006 C/K Truck Service Manual. 2. Lower the vehicle in order to work through the front wheelhouse opening. 3. Remove the power steering pump heat shield bolts. 4. Remove the heat shield from the vehicle. Installation Procedure 1.
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Suspension Table of Contents 3-1 Section 3 Suspension Front Suspension .....................................3-3 Specifications .......................................................3-3 Repair Instructions...............................................3-5 Jounce Shock Absorber Replacement ...............3-5 Lower Jounce Shock Control Arm Replacement.......................................................3-6 Description and Operation ..................................3-8 Front Enhanced Suspension .........
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3-2 Table of Contents Suspension BLANK 2006 LSSV Service Manual Supplement
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Suspension Front Suspension 3-3 Front Suspension Specifications Fastener Tightening Specifications Specification Application Metric English Jounce Shock Lower Bolt 125 N•m 92 lb ft Jounce Shock Upper Bolt 125 N•m 92 lb ft Lower Jounce Control Arm Brace Bolt 72 N•m 53 lb ft Lower Jounce Control Arm Pivot Bolt 244 N•m 180 lb ft 2006 LSSV Service Manual Supplement
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3-4 Front Suspension Suspension BLANK 2006 LSSV Service Manual Supplement
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Suspension Front Suspension 3-5 Repair Instructions Jounce Shock Absorber Replacement Inspection Procedure Prior to replacement inspect the following: • Oil leaks on the shaft or around the Schrader value • Rod guide to shaft end should be 7.0 cm ± 4.0 mm (2.75 in ± 0.15 in) Pry up on the alignment arm and release the arm should smoothly extend without binding. Removal Procedure Caution: Refer to Vehicle Lifting Caution in Cautions and Notices.
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3-6 Front Suspension Suspension Lower Jounce Shock Control Arm Replacement Removal Procedure Caution: Refer to Vehicle Lifting Caution in Cautions and Notices. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in 2006 C/K Truck Service Manual. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels in 2006 C/K Truck Service Manual. 3. Remove the jounce shock absorber. Refer to Jounce Shock Absorber Replacement. 4.
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Suspension Front Suspension 3-7 2. Verify that the alignment of the jounce lower control arm (2) and stabilizer bushing link (1) of the factory control arm are within the specification. Add shims until the specification is correct. Specification A 5 mm ± 3.5 mm (0.20 in ±0.14 in). 3. Install the outer shim and control arm brace, ensure that the pivot nut and brace slots are aligned. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the 2 brace bolts (1) and tighten.
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3-8 Front Suspension Description and Operation Front Enhanced Suspension The front suspension has two primary purposes: • Isolate the driver from irregularities in the road surface. • Define the ride and handling characteristics of the vehicle. The front suspension absorbs the impact of the tires traveling over irregular road surfaces and dissipates this energy throughout the suspension system. This process isolates the vehicle occupants from the road surface.
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Suspension Rear Suspension 3-9 Rear Suspension Specifications Fastener Tightening Specifications Specification Application Metric English Jounce Shock Frame Mount Bracket Bolts 72 N•m 53 lb ft Jounce Shock to Mount Bolts 12 N•m 9 lb ft Shock Absorber Cover Bolts 35 N•m 26 lb ft Shock Absorber Lower Nuts 90 N•m 66 lb ft 2006 LSSV Service Manual Supplement
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3-10 Rear Suspension Suspension BLANK 2006 LSSV Service Manual Supplement
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Suspension Rear Suspension 3-11 Repair Instructions Rear Jounce Shock Absorber Replacement Inspection Procedure Prior to replacement inspect the following: • Oil leaks on the shaft or around the Schrader value • Correct shaft to pad contact location • Rod guide to shaft end should be 10.67 cm ± 0.15 mm (4.20 in ± 0.15 in) Pry up on the shaft end and release the arm should smoothly extend without binding. Removal Procedure 1. Remove the rear jounce shock absorber mount.
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3-12 Rear Suspension Suspension Rear Jounce Shock Absorber Mount Replacement Removal Procedure Caution: Refer to Vehicle Lifting Caution in Cautions and Notices. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in 2006 C/K Truck Service Manual. 2. Remove the nuts (2) and bolts (4) from the mount. 3. Remove bolts (1) from the mount. 4. Remove the mount (3) and shock as an assembly from the vehicle. Installation Procedure 1.
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Suspension Rear Suspension 3-13 3. Remove shock cover nuts (3) and bolts (4). 4. Remove the lower shock nut (1) and bolt (2). 5. Remove the shock cover pieces from the axle. Installation Procedure 1. Install the shock cover pieces on the axle. Ensure that the tab on the upper cover is in the slot of the lower cover. 2. Install the lower shock bolt (2) and nut (1). 3. Install bolts (4) and nuts (3) into the shock cover. 4. Install the top shock cover bolt (1).
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3-14 Rear Suspension Suspension Shock Absorber Cover Replacement – Right Removal Procedure Caution: Refer to Vehicle Lifting Caution in Cautions and Notices. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in 2006 C/K Truck Service Manual. 2. Remove bolts (6) and nuts (4) from the cover. 3. Remove bolt (2) from the shock cover. 4. Remove nut (3) and bolt (8) from the shock. 5. Remove shock covers pieces (1, 5, 7) from the axle housing. Installation Procedure 1.
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Suspension Description and Operation Rear Enhanced Suspension All models use a rear spring suspension system and a solid rear axle suspension system. The rear axle is attached to the multi-rear springs by U-bolts. The front of the spring ends are attached to the frame at the front hangers through rubber bushings. The rear of the spring ends are attached to the frame with shackles that allow the springs to change their length, due to the spring compressing, while the vehicle is in motion.
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3-16 Rear Suspension Suspension BLANK 2006 LSSV Service Manual Supplement
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Suspension Rear Suspension 3-17 Tires and Wheels Specifications Fastener Tightening Specifications Specification Application Metric English 81 N•m 60 lb ft 102-108 N•m 75-80 lb ft 35 N•m 26 lb ft 9 N•m 80 lb in Spare Tire Carrier Latch Mechanism Bolt 25 N•m 18 lb ft Spare Tire Carrier Latch Mounting Bolts 97 N•m 72 lb ft Spare Tire Carrier Mount Bolts (Bed Mount) 68 N•m 50 lb ft Spare Tire Carrier Pivot Bolt Bracket Bolts 97 N•m 72 lb ft Spare Tire Carrier Torx Bolts (In Vehicle) 5
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3-18 Tires and Wheels Suspension Component Locator Tires and Wheels Component Views Beadlock Wheel Legend (1) Rear Half of Wheel (4) O-ring Seal (2) Beadlock (5) Front Half of Wheel (3) Tire (6) Tire Pressure Monitor Sensor and Retaining Clip 2006 LSSV Service Manual Supplement
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Suspension Tires and Wheels 3-19 Repair Instructions Tire Mounting and Dismounting (Beadlock) Tools Required D528235-H1 Run Flat Lubricant Dismounting Procedure Outer Half 1. Remove the air valve core to fully deflate the tire. Ensure that valve air passage is not blocked. 2. Remove all balance weights from the wheel flange. 3. Place the tire on a flat surface with the nuts facing up. 4. Loosen all the nuts in a star pattern until all the nuts have been removed. 5.
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3-20 Tires and Wheels Suspension 7. Install the pry bar between the flange and the tire then push up. The blade of the pry bar will push the tire down and off of the 5° beadseat. 8. Using the tire spoon (2) and pry bar (1) at intervals of 45°, work around the wheel and tire. Important: Ensure that the wheel half is placed with the O-ring side facing up to avoid scratching the surface. 9. Remove the outer wheel from the tire and remove the Oring and discard. 10.
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Suspension Tires and Wheels 3-21 16. Locate the air pressure sensor (1) and compress the beadlock insert down enough to expose the sensor. 17. Remove the sensor from the beadlock insert. 18. Stand the tire on end allowing one side of the beadlock to fall off-center into the tire chamber. 19. Place the tire back on the ground and compress the beadlock in an oval shape and twist and pull out of the tire cavity. Cleaning and Inspection Procedure 1.
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3-22 Tires and Wheels Suspension 2. Inspect the following areas: • Outer wheel half for wear, damage or warpage. • Inner wheel half for wear, damage or warpage. • Beadlock for wear or damage. Replace any worn or damaged parts. Mounting Procedure 1. Place the tire on a horizontal surface. Compress the beadlock from its round shape into an oval. 2. Holding the beadlock with both hands, rotate it and place it into the tire cavity.
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Suspension Tires and Wheels 3-23 6. Center the wheel air fitting with one of the grooves in the beadlock and press inner wheel into tire. 7. Install the air valve into the rim pulling into position. 8. On the outer wheel apply a small amount of run flat lubricant D528235-H1 to the O-ring groove and install the O-ring. Remove excess of lubricant. Important: Ensure that both inner wheel sealing surfaces are completely free of any debris. 9. Install the outer wheel into the tire.
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3-24 Tires and Wheels Suspension Notice: Refer to Fastener Notice in Cautions and Notices. Important: The specified torque pattern must be followed to prevent damage or improper sealing. Important: Retorque wheel nuts in a star pattern at 80-161 KM (50-100 MI) and 8047 KM (5,000 MI) thereafter retorque to 102108 N•m (75-80 lb ft). 11. Using the torque pattern, tighten the nuts. Tighten • Tighten the wheel nuts (first pass) to 81 N•m (60 lb ft).
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Suspension Tires and Wheels 3-25 Spare Tire Carrier Replacement (In Vehicle) Removal Procedure 1. Remove the spare tire. Refer to Spare Tire Replacement (In Vehicle). 2. Remove the hex bolts (1) from the carrier. 3. Remove the torx bolts (2) from the carrier. 4. Remove the carrier (3) from the vehicle. Installation Procedure 1. Install the carrier (3) into the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the torx bolts (2) and tighten.
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3-26 Tires and Wheels Suspension Installation Procedure 1. Install the carrier into the vehicle bed over the mounting holes. Notice: Refer to Fastener Notice in Cautions and Notices. Important: Tighten the bolts in the following sequence. 2. Using the aid of an assistant position the reinforcement bracket under the bed and install bolts (1, 2). Tighten 2.1. Tighten the long carrier bolts (1) to 68 N•m (50 lb ft). 2.2. Tighten the short carrier bolts (2) to 68 N•m (50 lb ft). 3.
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Suspension Tires and Wheels 3-27 Installation Procedure 1. Install the carrier into the bracket. 2. Install any shims or washers and install the pivot bolt (1). 3. Lubricate the pivot joint with chassis lubricant. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication. 4. Install the nut (2) onto the pivot bolt and tighten until slight pivoting resistance is felt. 5. Install the spare tire onto the spare tire carrier. Notice: Refer to Fastener Notice in Cautions and Notices. 6.
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3-28 Tires and Wheels Suspension 3. Remove the lower pivot mount bolts (1). Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices. 1. Install the lower pivot bracket onto the bumper and install the bolts (1). Tighten Tighten the lower pivot mount bolts to 97 N•m (72 lb ft). 2. Install the upper mount onto the bumper and install the pivot bolt through both mounts. 3. Install the upper mount pivot bolts (1). Tighten Tighten the upper pivot mount bolts to 97 N•m (72 lb ft). 4.
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Suspension Tires and Wheels 3-29 Spare Tire Carrier Latch Replacement (Swing Away) Removal Procedure 1. Unlatch and open the spare tire carrier swing arm. 2. Remove the bolts (1) securing the latch to the bumper. 3. Remove the latch from the vehicle. Disassemble Procedure 1. 2. 3. 4. Remove the latch mechanism bolts, nuts, and spacers. Remove the latch mechanism. Remove the latch mechanism isolator bolts. Remove the latch mechanism isolator.
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3-30 Tires and Wheels Suspension Service/Maintenance Information 1. Check the latch isolator (2) for damage, replace as required. 2. Thoroughly clean the latch casting surfaces and bond the NEW isolator in place using Loctite Black Max 380® adhesive or equivalent. 3. Check for operation and apply Teflon dry lube GM P/N 12371287 (Canadian P/N 10953437) to the latch mechanism (1) as required. Assembly Procedure 1. Install the latch mechanism isolator, if necessary.
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Suspension Tires and Wheels 3-31 Installation Procedure 1. Install the latch bolts (1) on the bumper. Ensure that the secondary latch cable is also installed and is facing down. 2. Adjust the carrier latch. Refer to Spare Tire Carrier Latch Adjustment (Swing Away). 3. Close and ensure that the spare tire carrier is latched. Spare Tire Carrier Latch Adjustment (Swing Away) 1. Loosen the latch bolts (1). 2. Swing the carrier into the latch pocket so the striker pin touches the latch mechanism. 3.
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3-32 Tires and Wheels Suspension Spare Tire Replacement (In Vehicle) Removal Procedure Caution: Be careful not to drop tire and wheel assemblies on your hands and feet. Lift properly, using your legs as well as your body. Tires and wheels are heavy and can cause injury if not handled correctly. 1. Remove the wheel nut (4) and washer (1). 2. Remove the spare tire retainer (2). 3. With the aid of an assistant remove the spare tire (3) from the vehicle. Installation Procedure 1.
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Suspension Tires and Wheels 3-33 Description and Operation General Description The spare tire is located under the rear end of non EMP vehicles. For exact locations refer to the 2006 LSSV Owners Manual Supplement. The hoist shaft allows a link between the tire hoist and the rear bumper. The factory spare tire hoist tools are used to remove the spare. An access hole in the rear of the bumper is provided to allow access. If the tire hoist is damaged it must be replaced.
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D 5 2 83 5 -H 1 3-34 Tires and Wheels Suspension Special Tools and Equipment Illustration Tool Number/ Description Run Flat Lubricant 2006 LSSV Service Manual Supplement
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Suspension Tire Pressure Monitoring 3-35 Tire Pressure Monitoring Specifications Fastener Tightening Specifications Specification Application Metric English Tire Pressure Monitoring Gage Nuts 0.8 N•m 7 lb in Tire Pressure Monitoring Receiver Bolts 0.
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Tire Pressure Monitoring System Schematics 3-36 Tire Pressure Monitoring 2006 LSSV Service Manual Supplement Suspension
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Suspension Tire Pressure Monitoring 3-37 Component Locator Tire Pressure Monitoring System Component Views Monitoring Gage Legend (1) Function Display Gage (7) Tire Rotation Program (2) Programmed Wheel Position (8) Cold Pressure Program (3) Alarm Light (9) Programming Mode (4) Low Pressure Indicator (10) Units of Pressure or Temperature (5) Alert Indicator (11) Numerical Display (6) Learn Mode (12) Towing Vehicle Indicator 2006 LSSV Service Manual Supplement
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3-38 Tire Pressure Monitoring Suspension Switch Panel Legend (1) Learn Mode Button (3) Mode Button (2) Set Button (4) System Switch Panel 2006 LSSV Service Manual Supplement
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Suspension Tire Pressure Monitoring 3-39 Programming Initiator Legend (1) Programming Initiator (4) Learn Button (2) Status LED (5) De-Energize Button (3) ON/OFF Switch (6) Initiate Button 2006 LSSV Service Manual Supplement
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3-40 Tire Pressure Monitoring Suspension Receiver Tire Pressure Monitoring System Connector End Views Monitoring Gage Connector Part Information Connector Part Information • 12047785 • 4-Way F Metri-Pack 150 (BK) Wire Color Circuit No. Pin A RD 243 Battery Positive Voltage B BK 1050 Ground C BN 9 D ___ ___ • 174823-1 • 4-Way F (WH) Wire Color Circuit No.
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Suspension Tire Pressure Monitoring 3-41 Diagnostic Information and Procedures DTC E1 Conditions for Setting the DTC This DTC indicates that there may be broken tire sensors or a malfunctioning receiver unit. Mismatches in tire sensor ID may also cause this problem.
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3-42 Tire Pressure Monitoring Suspension DTC E4 Conditions for Setting the DTC This DTC will usually represent an internal fault. Try powering the unit OFF and ON to clear this DTC. If this DTC continuously occurs the unit may have to be replaced.
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Suspension Tire Pressure Monitoring 3-43 Repair Instructions Tire Pressure Monitoring Receiver Replacement Removal Procedure 1. Remove the I/P knee bolster panel. Refer to Knee Bolster Replacement in Instrument Panel, Gages and Console in 2006 C/K Truck Service Manual. 2. Disconnect the power cable from the receiver. 3. Disconnect the display cable from the receiver. 4. Remove the bolts (1) and remove the receiver (2). Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices. 1.
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3-44 Tire Pressure Monitoring Suspension 5. Remove the nuts (1) from the back of the gage. 6. Remove the gage bracket (2). 7. Remove the gage from the housing. Installation Procedure 1. Install the gage into the housing opening. 2. Install the bracket (2) on the back of the gage. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the nuts (1) on the gage studs. Tighten Tighten the nuts to 0.8 N•m (7 lb in). 4. Install the electrical connectors onto the gage. 5.
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Suspension Tire Pressure Monitoring 3-45 Tire Pressure Monitoring Switch Panel Replacement Removal Procedure 1. Remove the I/P knee bolster panel. Refer to Knee Bolster Replacement in Instrument Panel, Gages and Console in 2006 C/K Truck Service Manual. 2. Disconnect the switch panel cable from the receiver. 3. Remove any wiring harness straps securing the cable to the vehicle. Note position of straps for reinstallation. 4. Pull the switch Panel off of the instrument panel cluster (IPC) trim plate bezel.
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3-46 Tire Pressure Monitoring Suspension 4. Separate the transmitter sensor from the bracket. 5. Inspect all parts and replace as needed. Installation Procedure 1. Install the transmitter sensor into the bracket. 2. Install the pressure transmitter sensor assembly. Refer to Tire Mounting and Dismounting (Beadlock) in Tires and Wheels. 3. Install the tire. Refer to Tire and Wheel Removal and Installation in Tires and Wheels in 2006 C/K Truck Service Manual. 4. Lower the vehicle.
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Suspension Tire Pressure Monitoring 3-47 Level 1 Cold Inflation Pressure Important: This function changes the cold inflation pressure for each axle. For tire pressure setting specifications refer to Tire Inflation Pressure Specifications in Maintenance and Lubrication. Factory default 2.41 Bar (35 psi). 1. Enter Level 1 Programming Mode. Refer to Entering Programming Modes. 2. Press the TIRE button to scroll to the desired axle. The tires of the selected axle are filled in. 3.
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3-48 Tire Pressure Monitoring Suspension 4. 5. 6. 7. Press the MODE button to view the current value. Press the TIRE button to increase the value. Press the MODE button to decrease the value. Press the SET button to save when the desired value is reached. Important: Repeat programming steps 2-7 until Low-Pressure warning levels are set for all axles as desired. 8. Press the SET button to exit. 9. Press the SET button again to revert to normal view.
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Suspension Tire Pressure Monitoring 3-49 High Temperature Alert Important: This function changes the high-temperature alert threshold. Factory Default 80°C (176°F). 1. Enter Level 1 Programming Mode. Refer to Entering Programming Modes. 2. To enter, press the MODE button until the alert icon and temperature until are displayed. 3. Press the TIRE button to enter and display the current value of High Temperature Alert. 4. Press the TIRE button to increase the value. 5.
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3-50 Tire Pressure Monitoring Suspension Tire Rotation Important: This function is used after the tires are rotated and the new position needs to be updated. This procedure is valid for four tire locations only. 1. Enter Level 1 Programming Mode. Refer to Entering Programming Modes. 2. To enter, press the MODE button until the tire rotation icon is displayed. 3. Press the TIRE button to scroll to a tire position. Important: The current tire position number will be displayed. 4.
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Suspension Tire Pressure Monitoring 3-51 Level 2 Slope For Tire Pressure Setting Specifications refer to Tire Inflation Pressure Specifications in Maintenance and Lubrications. Important: Factory Default 44. The slope is a value corresponding to the rate of pressure change due to temperature for a particular tire. This value affects the calculation to determine pressure deviation value. 1. Enter Level 2 Programming Mode. Refer to Entering Programming Modes. 2.
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3-52 Tire Pressure Monitoring Suspension 5. A new transmitter identification can be learned in two ways: • Vigorously shake the transmitter to provoke a transmission. • By inflating or deflating the tire by more than 0.2 Bar (3 psi). 6. To remove the transmitter from the selected tire location, press the MODE button. Important: To prevent the last identification from being erased, scroll to the next tire position before driving.
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Suspension Tire Pressure Monitoring 3-53 The receiver that is installed on the vehicles needs to have a unique sensor identification code for each wheel position programmed into it to ensure proper orientation of the system. Each wheel assembly has a sensor in it that can be activated using the initiator. When the sensor is activated, it sends out its unique identification code, which is then stored in the memory of the receiver so that it knows which sensors belong to that vehicle.
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3-54 Tire Pressure Monitoring Suspension 7. Determine the actual sensor location (normally located adjacent to the valve stem) on the wheel to be programmed. Position the initiator (1) against the tire’s sidewall for that sensor location, press the LEARN button and hold the unit steady for at least 5 seconds. The flashing wheel icon on the gage display will become filled in when the sensor ID has been successfully captured by the receiver. (If this does not occur, repeat step 7.
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Suspension Tire Pressure Monitoring 3-55 propellants in any tire/wheel assembly may adversely affect the operation of the Sensor/Transmitters. Description and Operation Tire Pressure Monitor Description and Operation The system is a sensing device designated to identify and display tire operating data and activate an alert or warning when tire pressure or temperature irregularities are detected.
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3-56 Tire Pressure Monitoring The reference pressure, or COLD PRESSURE is the air pressure inside the tire inflated at room temperature 18°C (64°F) to the vehicle manufacturer’s recommendation. When a tire heats up, the air pressure inside the tire can also be expected to increase. For example, a normal or “required” pressure at 64°F or 18°C may be 2.35 Bar (34 psi) and a normal pressure at 49°C (120°F) may be 2.7 Bar (39 psi). Both pressure readings are correct at their respective temperatures.
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Suspension Tire Pressure Monitoring 3-57 Special Tools and Equipment Illustration Tool Number/ Description 090.
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3-58 Tire Pressure Monitoring Suspension BLANK 2006 LSSV Service Manual Supplement
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Driveline/Axle Table of Contents 4-1 Section 4 Driveline/Axle Front Drive Axle ........................................4-3 Transfer Case ...........................................4-7 Repair Instructions...............................................4-3 Front Axle Vent Tube Filter Replacement ..........4-3 Description and Operation ..................................4-4 Front Axle Vent Tube Filter Description..............4-4 Repair Instructions ..............................................
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4-2 Table of Contents Driveline/Axle BLANK 2006 LSSV Service Manual Supplement
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Driveline/Axle Front Drive Axle 4-3 Front Drive Axle Repair Instructions Front Axle Vent Tube Filter Replacement Removal Procedure 1. Loosen the clamps (1) securing the filter (2). 2. Remove the filter from the hoses and discard. Installation Procedure Important: The filter arrow must point toward the axle vent pipe. If replacing the hose, the length of the new hose must match the length of the old hose. 1. Install the filter (2) to the hoses. 2. Position hose clamps (1) and tighten.
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4-4 Front Drive Axle Description and Operation Front Axle Vent Tube Filter Description The front axle is specially equipped with a vent tube filter to protect the axle from contaminants found in the off-road environment. The vent filter is attached to a hose with a vented cap at the end, and is mounted in the engine compartment next to the left inner wheel housing. The filter must be inspected occasionally to see if it needs to be replaced. Refer to Owner Checks and Services in Maintenance and Lubrication.
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Driveline/Axle Rear Drive Axle 4-5 Rear Drive Axle Repair Instructions Rear Axle Vent Tube Filter Replacement Removal Procedure Caution: Refer to Vehicle Lifting Caution in Cautions and Notices. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in 2006 C/K Truck Service Manual. 2. Install safety stands. 3. Remove the clamps (2) holding the filter (1) to the hoses. 4. Remove the filter and discard.
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4-6 Rear Drive Axle Description and Operation Rear Axle Vent Tube Filter Description The rear axle is specially equipped with a vent tube filter to protect the axle from contaminants found in the off-road environment. It is attached to a hose with a vented cap at the end. The rear axle vent filter is mounted near the top of the axle housing and the hose is attached to the brake bracket on the driver’s side frame rail. The filter must be inspected occasionally to see if it needs to be replaced.
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Driveline/Axle Transfer Case - NVG 261-NP2 4-7 Transfer Case - NVG 261-NP2 Repair Instructions Transfer Case Vent Tube Filter Replacement Removal Procedure Caution: Refer to Vehicle Lifting Caution in Cautions and Notices. Important: The filter is located on the left side of the vehicle. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in 2006 C/K Truck Service Manual. 2. Install safety stands. 3. Remove the clamps (2) holding the filter (1) to the hoses. 4.
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4-8 Transfer Case - NVG 261-NP2 Description and Operation Transfer Case Vent Tube Filter Description The transfer case is specially equipped with a vent tube filter to protect the transfer case from contaminants found in the off-road environment. The vent filter is attached to a hose with a vented cap at the end, and is mounted under the vehicle next to the left side of the transfer case. The filter must be inspected occasionally to see if it needs to be replaced.
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Brakes Table of Contents 5-1 Section 5 Brakes Disc Brakes............................................... 5-3 Specifications .......................................................5-3 Repair Instructions...............................................5-5 Rear Brake Caliper Cover Replacement ............5-5 Rear Brake Caliper Bolt Replacement................
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5-2 Table of Contents Brakes BLANK 2006 LSSV Service Manual Supplement
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Brakes Disc Brakes 5-3 Disc Brakes Specifications Fastener Tightening Specifications Specification Application Metric English Brake Caliper Bolt 108 N•m 80 lb ft Brake Caliper Bracket Bolt 300 N•m 221 lb ft Brake Caliper Nut 45 N•m 33 lb ft 2006 LSSV Service Manual Supplement
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5-4 Disc Brakes Brakes BLANK 2006 LSSV Service Manual Supplement
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Brakes Disc Brakes 5-5 Repair Instructions Rear Brake Caliper Cover Replacement Removal Procedure Caution: Refer to Vehicle Lifting Caution in Cautions and Notices. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in the 2006 C/K Truck Service Manual. 2. Remove the cover nuts (3). 3. Remove the caliper cover (2). 4. If damaged, remove the caliper bolts (1). Refer to Rear Brake Caliper Bolt Replacement. Installation Procedure 1.
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5-6 Disc Brakes Brakes 5. Compress the brake caliper pistons. • Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. • Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. • Remove the C-clamp from the caliper. 6. Remove the rear brake caliper cover. Refer to Rear Brake Caliper Cover Replacement. 7. Loosen the rear brake caliper mounting bolts. Do not remove. 8. Remove the brake caliper bracket bolts (2).
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Brakes Disc Brakes 5-7 2. Install the caliper and caliper bracket (1) as an assembly. 3. Perform the following procedure before installing the caliper bracket bolts. • Remove all traces of the original adhesive patch. • Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. • Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the brake caliper bracket bolts (2).
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5-8 Disc Brakes Brakes BLANK 2006 LSSV Service Manual Supplement
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Engine Table of Contents 6-1 Section 6 Engine Engine Electrical.......................................6-3 Specifications .......................................................6-3 Schematic and Routing Diagrams......................6-4 Component Locator .............................................6-9 Engine Electrical Component Views..................6-9 Engine Electrical Connector End Views ...........6-14 Diagnostic Information and Procedures..........
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6-2 Table of Contents Engine BLANK 2006 LSSV Service Manual Supplement
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Engine Engine Electrical 6-3 Engine Electrical Specifications Fastener Tightening Specifications Specification Application Metric English Battery Cable Connections 17 N•m 13 lb ft Battery Cable Frame Bolt 25 N•m 18 lb ft Battery Retainer Bolt 25 N•m 18 lb ft Front Junction Block Nut 9 N•m 80 lb in Generator Mounting Bolts 50 N•m 37 lb ft Generator Output Stud Nut 9 N•m 80 lb in MEGA Fuse 175 amp 12 N•m 110 lb in MIDI Fuse 50 amp 4 N•m 35 lb in Negative Battery Cable to Block Bol
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6-4 Engine Electrical Engine MEGA Fuse/MIDI Fuse Specifications Fuse Type MEGA Fuse 175 Ampere MIDI Fuse 50 Ampere Fuse Part Number MEGA Fuse 0298-175 MIDI Fuse 0498-050 Stamp Color Code Identifiers MEGA Fuse White MIDI Fuse Black Fuse Holder Part Number MEGA Fuse 0298-101 MIDI Fuse 0498-0900 Ambient Temperature Operating Range MEGA Fuse -40°C to + 125°C MIDI Fuse -40°C to + 125°C Schematic and Routing Diagrams 2006 LSSV Service Manual Supplement
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Engine Electrical 6-5 Starting and Charging Schematics (Battery Schematic) Engine 2006 LSSV Service Manual Supplement
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Starting and Charging Schematics (Charging Schematics – 12V) 6-6 Engine Electrical 2006 LSSV Service Manual Supplement Engine
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Engine Electrical 6-7 Starting and Charging Schematics (Charging Schematics – 24V) Engine 2006 LSSV Service Manual Supplement
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Starting and Charging Schematics (Winch Prep Wiring Schematics) 6-8 Engine Electrical 2006 LSSV Service Manual Supplement Engine
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Engine Engine Electrical 6-9 Component Locator Engine Electrical Component Views 24V Slave Start Receptacle Assembly – LSSV Legend (1) Battery Negative Cable (4) Slave Start Receptacle (2) Mounting Bracket (5) Battery Positive Cable (3) Slave Start Receptacle Cover 2006 LSSV Service Manual Supplement
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6-10 Engine Electrical Engine Bulkhead Junction Block Legend (1) Junction Block (6) Negative Winch Prep Cable – Rear (2) Jumper Plate (7) Positive Winch Prep Cable – Rear (3) Ground Connection (8) Battery Positive Cable – Right (4) Mounting Bracket (9) Battery Positive Cable – Frame Mounted (5) Battery Negative Cable – Right 2006 LSSV Service Manual Supplement
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Engine Engine Electrical 6-11 Winch Cable and Starter Junction Block Legend (1) Battery Positive Cable (4) Junction Block Post Nut (2) Junction Block (5) Positive Winch Prep Cable – Front (3) Generator Output Cable (6) Junction Block Post 2006 LSSV Service Manual Supplement
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6-12 Engine Electrical Engine Generators – Diesel Legend (1) Generator – Right (24V) (2) Engine 2006 LSSV Service Manual Supplement (3) Generator – Left (12V)
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Engine Engine Electrical 6-13 Left Front Corner of the Engine Compartment Legend (1) Fuse/Relay Center Underhood (4) Vehicle Load Disconnect Switch 50 amp (MIDI) Fuse (2) Battery – Left (24V) (5) Vehicle Load Disconnect Switch 175 amp (MEGA) Fuse (3) Junction Block Underhood 2006 LSSV Service Manual Supplement
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6-14 Engine Electrical Engine Vehicle Load Disconnect Switch Engine Electrical Connector End Views 24V Generator Relay Connector Part Information Connector Part Information • 12129716 • 4-Way F MP Series 280 (GY) Wire Color Circuit No. Pin Function 30 BN 8008 Operator Field Duty Cycle Signal 85 PK 8002 UBEC Cavity A3 86 BK 150 Ground 87 RD/BK 8009 24V Battery Supply Voltage • 35–223 • 4-Way Pin Wire Color Circuit No.
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Engine Engine Electrical 6-15 Winch Prep Connector – Rear Connector Part Information • TX017640 • 2-Way (RD) Pin Wire Color Circuit No.
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6-16 Engine Electrical Diagnostic Information and Procedures Diagnostic Starting Point – Engine Electrical Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation.
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Engine Jump Starting in Case of Emergency Engine Electrical 6-17 • Do not expose the battery to open flames or sparks. • Do not allow battery acid to contact the eyes or the skin. • Flush any contacted areas with water immediately and thoroughly. • Get medical help. You should always use the slave receptacle (1) and NATO Slave Cable when performing this operation.
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6-18 Engine Electrical Engine eyes or on your skin, flush the place with water and get medical help immediately. Caution: Keep hands, tools, and clothing away from the electric engine coolant fans in order to help prevent personal injury. These fans are electric and can turn on whether or not the engine is running. The fans can start automatically with the ignition in the ON position. 4. Connect the slave cable to the vehicle with the dead battery. 5. Start the vehicle with the good batteries. 6.
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Engine Engine Electrical 6-19 24V Generator Noise Diagnosis (cont’d) Step Action Yes No Go to Step 10 Go to Step 3 Go to Step 4 Go to Step 10 Go to Step 11 Go to Step 5 System OK Go to Step 6 Go to Step 7 Go to Step 8 System OK Go to Step 8 Go to Step 9 Go to Step 10 1. Start the engine. Verify that the noise can be heard. 2. Turn OFF the engine. 2 3. Disconnect the 4-way connector from the generator. 4. Start the engine. 5. Listen for the noise. Has the noise stopped? 1.
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6-20 Engine Electrical Engine 24V Generator Noise Diagnosis (cont’d) Step 9 Action Yes No System OK Go to Step 11 System OK Go to Step 11 Go to Step 12 Go to Step 2 System OK Go to Step 2 1. Replace the drive belt tensioner. Refer to Drive Belt Tensioner Replacement in Engine Mechanical – 6.6L in 2006 C/K Truck Service Manual. 2. Start the engine. Has the noise decreased or stopped? 10 11 Compare the vehicle with a known good vehicle.
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Engine Engine Electrical 6-21 24V Generator Inoperative (cont’d) Step 6 Action Connect a test lamp between terminal 30 of the 24V relay and ground. Value(s) 7 8 9 10 Go to Step 17 ___ 11 12 13 ___ 14 15 16 Operate the system in order to verify the repair.
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6-22 Engine Electrical Engine BLANK 2006 LSSV Service Manual Supplement
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Engine Engine Electrical 6-23 Repair Instructions Battery and Battery Tray Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the battery cables. Refer to Battery Cable Disconnect/Connect Procedure. 2. Remove the battery tray support bracket bolt (3). 3. Loosen the bolts (1). Push up the battery tray (2) and remove from frame. 4. Unsnap the positive battery cable cover. 5. Remove the positive battery cable. 6.
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6-24 Engine Electrical Engine 3. Remove the connector position assurance (CPA) devices or secondary locks. 4. Separate the relay (1) from the wiring harness connector (2). Installation Procedure 1. Connect the relay (1) to the wiring harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the 24V relay (1) onto the underhood junction block. 4. Secure the wiring harness to the clip (2).
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Engine Engine Electrical 6-25 24V Generator Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the battery cables. Refer to Battery Cable Disconnect/Connect Procedure. 2. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical – 6.6L in the 2006 C/K Truck Service Manual. 3. Disconnect the generator electrical connector. 4. Remove the cable from the output stud. 5. Remove the generator bolts. 6.
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6-26 Engine Electrical Engine 3. Install the generator into the mounting bracket. 4. Install the generator bolts. Tighten Tighten generator bolts to 50 N•m (37 lb ft). 5. Connect the generator electrical connector. 6. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical – 6.6L in the 2006 C/K Truck Service Manual. 7. Connect the battery cables. Refer to Battery Cable Disconnect/Connect Procedure. Battery Cable Disconnect/Connect Procedure Removal Procedure 1.
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Engine Engine Electrical 6-27 Installation Procedure Important: Clean any existing corrosion from the battery terminal bolt flange and the battery cable end. 1. Install the positive cable to the 24V battery. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the battery ground negative cable to the 24V battery. Tighten Tighten the bolt to 17 N•m (13 lb ft). 3. Install the negative battery cable to the right underhood battery. Tighten Tighten the bolt to 17 N•m (13 lb ft). 4.
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6-28 Engine Electrical Engine 3. 4. 5. 6. Remove the switch mounting nuts and bolts (1). Remove the cable cover mounting screws (2). Remove the switch cable cover (3). Remove the nuts holding the 24V and 12V cables to the switch and remove the cables. Note location of cables removed for assembly. Installation Procedure Notice: Refer to Fastener Notice in Cautions and Notices. 1. Install the 24V and 12V cables to the switch and install the cable mounting nuts.
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Engine Engine Electrical 6-29 5. Install the switch key (1) (if removable) to the switch (2). 6. Connect the battery cables. Refer to Battery Cable Disconnect/Connect Procedure. 12V Battery Positive Cable Replacement – Battery to Battery Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the battery cables. Refer to Battery Cable Disconnect/Connect Procedure. 2.
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6-30 Engine Electrical Engine 5. Install the positive battery bolt cable bolt through the cable and into the positive battery terminal of the right rear underhood battery. Tighten Tighten the bolt to 17 N•m (13 lb ft). 6. Connect the battery cables. Refer to Battery Cable Disconnect/Connect Procedure. 12V Battery Negative Cable Replacement – Frame Mounted Battery Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the battery cables.
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Engine Engine Electrical 6-31 Front Winch Harness and Connector Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the battery cables. Refer to Battery Cable Disconnect/Connect Procedure in Engine Electrical. 2. Remove the positive cable (1) from the junction block (2). 3. Remove the negative cable from the engine block. 4. Remove any wiring harness straps securing the cable to the vehicle. 5.
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6-32 Engine Electrical Engine 3. Install the negative cable to the engine and the fastening bolt. Tighten Tighten the negative cable bolt to 34 N•m (25 lb ft). 4. Install the positive cable (1) to the junction block (2). Tighten Tighten the junction block nut to 9 N•m (80 lb in). 5. Install connector/harness to vehicle in original location using wiring harness straps. 6. Connect the battery cables. Refer to Battery Cable Disconnect/Connect Procedure.
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Engine Engine Electrical 6-33 Installation Procedure 1. Install the cable (2) onto the vehicle in the same location as removed. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the connector onto the bracket and secure with bolt (1). Tighten Tighten the connector bolt to 10-15 N•m (7-11 lb ft). 3. Install the clamp and secure with bolt. 4. Working from the rear to the front of the vehicle install the wiring harness straps. 5. Install the positive cable (1) to the junction block (2).
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6-34 Engine Electrical Engine 6. Disconnect the slave receptacle connectors from the slave receptacle. Refer to Slave Receptacle Replacement (LSSV). 7. Remove the wiring harness straps securing the slave receptacle harness and the blackout (B/O) harness. 8. Remove the slave receptacle harness from the bumper assembly. Installation Procedure Important: Verify all connections are clean prior to installation. 1. Position the slave receptacle harness onto the bumper assembly. 2.
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Engine Engine Electrical 6-35 Slave Receptacle Replacement (LSSV) Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the battery cables. Refer to Battery Cable Disconnect/Connect Procedure. 2. Unscrew the slave receptacle cover (1). 3. Remove the fasteners (2) securing the slave receptacle to the radiator grille guard bracket. 4. Remove the slave receptacle (3). 5. Disconnect the negative cable connections (2). 6.
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6-36 Engine Electrical Engine 4. Install the rubber cover onto the rear of the positive cable connection. 5. Position the slave receptacle cover onto the rear of the bracket. 6. Install the fasteners (2) onto the slave receptacle (3) and the slave receptacle cover (1). Tighten Tighten the bolts to 8 N•m (71 lb in). 7. Install the slave receptacle cover (1). 8. Connect the battery cables. Refer to Battery Cable Disconnect/Connect Procedure.
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Engine Engine Electrical 6-37 Notice: Note the locations of the cables removed for assembly. 5. Remove the cable retaining nuts holding the cables to the MEGA Fuse (1) or the MIDI Fuse (2) and remove the cables. 6. Remove MEGA Fuse 175 Amp (1) or MIDI Fuse 50 Amp (2) from vehicle. 2 Installation Procedure 1. Install new MEGA Fuse 175 Amp (1) or MIDI Fuse 50 Amp (2) to vehicle.
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6-38 Engine Electrical Engine Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the cables to the proper locations for the MEGA Fuse 175 Amp (1) or the MIDI Fuse 50 Amp (2). 3. Install the cable retaining nuts holding the cables to the fuse. Tighten • Tighten MEGA Fuse 175 Amp retaining nuts to 12 N•m (110 lb in). • Tighten MIDI Fuse 50 Amp retaining nuts to 4 N•m (35 lb in). Notice: MEGA Fuse 175 Amp cover shown, MIDI Fuse 50 Amp cover is same install. 4. Install the fuse cover (1).
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Engine Engine Electrical 6-39 Installation Procedure 1. Install the hold down bracket (2) into position on the battery. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the hold down bracket bolts (1). Tighten • Tighten upper battery hold down bolt to 9 N•m (80 lb in). • Tighten lower battery retainer bolt to 25 N•m (18 lb ft).
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6-40 Engine Electrical Description and Operation Battery Description (12V and 24V) Caution: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: • Always shield your eyes. • Avoid leaning over the battery whenever possible. • Do not expose the battery to open flames or sparks.
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Engine In a no load situation, with the engine OFF, the gage needle should be mid-way between the red band and green band, in the yellow band. If the gage needle is in the lower end of the yellow band, this is unacceptable, and the battery may be weak. Vehicle Load Disconnect Switch Opeartion This vehicle is equipped with a Vehicle Load Disconnect Switch.
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6-42 Engine Electrical Engine Special Tools and Equipment Illustration Tool Number/ Description J 42000 Battery Tester 2006 LSSV Service Manual Supplement
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Engine Engine Controls – 6.6L (LBZ) 6-43 Engine Controls – 6.
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6-44 Engine Controls – 6.
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Engine Engine Controls – 6.6L (LBZ) 6-45 Repair Instructions Engine Control Module (ECM) Replacement The ECM for the enhanced mobility package requires a special ECM calibration. Refer to Engine Control Module (ECM) Replacement in Engine Controls – 6.6L in the 2006 C/K Truck Service Manual and use the ECM Calibrations found in ECM Calibration Chart of this manual.
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6-46 Engine Controls – 6.6L (LBZ) Description and Operation Engine Control Module (ECM) Description The Enhanced Mobility Package (EMP) Engine Control Module (ECM) processes the various input information. The ECM sends the necessary electrical responses to control fuel delivery and other systems. The input information has an interrelation to more than one output. The option code EMP (RPO EM7) uses tires that have been changed from the original equipment size to those adapted to off-road usage.
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Body and Accessories Table of Contents 8-1 Section 8 Body and Accessories Body Front End ........................................ 8-3 Specifications....................................................... 8-3 Repair Instructions .............................................. 8-5 Upper Front Fender Reinforcement Replacement ...................................................... 8-5 Lower Front Fender Reinforcement Replacement ......................................................
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8-2 Table of Contents Enhanced Mobility Package Jack Mounting Bracket Replacement (Crew Cab) ................... 8-76 Enhanced Mobility Package Jack Tools Mounting Bracket Replacement ....................... 8-77 Lighting Systems ................................... 8-79 Specifications..................................................... 8-79 Schematic and Routing Diagrams ................... 8-79 Component Locator........................................... 8-88 Lighting Systems Component Views.............
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Body and Accessories Body Front End 8-3 Body Front End Specifications Fastener Tightening Specifications Specification Application Metric English Fender Bolt 25 N•m 18 lb ft Fender Reinforcement Bolt 10 N•m 89 lb in 2006 LSSV Service Manual Supplement
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8-4 Body Front End Body and Accessories BLANK 2006 LSSV Service Manual Supplement
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Body and Accessories Body Front End 8-5 Repair Instructions Upper Front Fender Reinforcement Replacement Removal Procedure 1. 2. 3. 4. Open the vehicle hood. Remove the upper reinforcement bolt (2). Remove the fender support bolt (1). Using a flat bladed tool, separate the upper reinforcement (3) from the bonding adhesive securing it to the fender. 5. Remove the upper reinforcement (3) from the fender. Installation Procedure 1. Remove any old panel bonding adhesive from the fender. 2.
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8-6 Body Front End Body and Accessories Installation Procedure 1. Remove any old panel bonding adhesive from the fender. 2. Apply panel bonding adhesive (5) to the lower reinforcement. 3. Install lower reinforcement (4) onto the fender. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the fender support bolt (1). Tighten Tighten the bolt to 25 N•m (18 lb ft). 5. Install the reinforcement bolt (2). Tighten Tighten the bolt to 10 N•m (89 lb in). 6. Close the vehicle hood.
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Body and Accessories Body Rear End 8-7 Body Rear End Specifications Fastener Tightening Specifications Specification Application Metric English Cargo Cover Bow Strap Retaining Nuts 5 N•m 44 lb in Cargo Cover Rail Bolts 8 N•m 70 lb in Cargo Cover Rail and Hinge/Upper Bolts 8 N•m 70 lb in Cargo Cover Rail Outer Bolts 26 N•m 19 lb ft Cargo Cover Strut Bolts 5 N•m 44 lb in 58-68 N•m 43-50 lb ft Fiberglass Top Bolts 2006 LSSV Service Manual Supplement
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8-8 Body Rear End Body and Accessories BLANK 2006 LSSV Service Manual Supplement
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Body and Accessories Body Rear End 8-9 Repair Instructions Fiberglass Top Replacement Removal Procedure 1. Disconnect the electrical connection for the dome lamp. 2. Remove the bolts (1) securing the top to the bed rails. 3. With the aid of an assistant, remove the top from the vehicle. 4. Remove the old sealer tape from the bed rails. Installation Procedure 1. Install the new sealer tape to the bed rails. 2. With the aid of an assistant, place the top on the bed rails.
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8-10 Body Rear End Body and Accessories 3. Remove the 4 bolts and nuts holding the 2 rail adapter plates to the side rail. 4. Remove the 2 bolts and nuts holding the bow hinge bracket. 5. Remove the side rail and adapter rail. 6. Remove the bow hinge bracket. 7. Remove the side rail. 8. Remove the side rail adapter. 9. Drill out the 4 existing rivnuts (if damaged) from the box rail. Installation Procedure 1. Apply 2 sided foam tape to the underside of the rails and to the edges of the mounting holes. 2.
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Body and Accessories Body Rear End 8-11 Notice: Refer to Fastener Notice in Cautions and Notices. Important: Do not use the jacknuts supplied in the kit. Use rivnuts (TX016183) instead. 3. Install the side rail over the adapter plates, with the 2 outer bolts and the 2 upper facing bracket bolts and nuts. Tighten • Tighten the 2 outer bolts to 26 N•m (19 lb ft). • Tighten the 2 upper facing bolts to 8 N•m (70 lb in). 4.
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8-12 Body Rear End Body and Accessories Installation Procedure 1. Apply 2 sided foam tape to the underside of the rails and to the edges of the mounting holes. Important: Do not use the jacknuts supplied in the kit. Use rivnuts (TX016183) instead. 2. Install the 4 rivnuts (if damaged) to the mounting holes using a rivnut installer. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the 2 front end rails to the front end of the box with 4 bolts over the 4 rivnuts.
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Body and Accessories Body Rear End 8-13 Cargo Cover Strut Replacement Removal Procedure 1. Remove the cargo cover, and the top bows. Refer to Cargo Cover Top Bows Replacement and Cargo Cover Strut Replacement. 2. Remove the 3 front strut bolts holding the 3 side struts to the hinge bracket. 3. Remove the 6 Nylock nuts. 4. Remove the 3 side struts with the 6 plastic bushings. (Replace if damaged.) Installation Procedure 1.
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8-14 Body Rear End Body and Accessories Installation Procedure 1. Slide the strap onto the top bows at the center. 2. Attach the retainer pin (1) assembly as shown at the base of each bow end. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Attach the retainer cover strap assembly (2) to the holes on both the left and right sides of the center top bow as shown. Attach the straps to the inboard sides of each with a nut. Tighten Tighten the 2 cover strap retaining nuts to 5 N•m (44 lb in). 4.
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Body and Accessories Installation Procedure Body Rear End 8-15 Important: All trailing edges must fall to the proper length at each side of the box rail. All tether ties must appear on the interior. Provide adequate slack between the bow straps and the cover. The new cover will be a tighter fit. 1. Install the cargo cover to the top bows and align so that the velcro strips are at the corners. 2. Install or attach all interior retainers to the bows, struts and loops. 3. Press the velcro flaps down. 4.
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8-16 Body Rear End Description and Operation Body Rear End Description These vehicles are equipped with several options including a cargo cover, troop seats (left and right) and fiberglass top. Cargo Cover The cargo cover is a rain waterproof, welded, plastic coated polyester top cover supported by bows and struts and attached by rails to the cargo box. It can be held down with hooks and buckles or velcroed closed. It may also be rolled up and secured with straps or folded and stowed while not in use.
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Body and Accessories Bumpers 8-17 Bumpers Specifications Fastener Tightening Specifications Specification Application Metric English 68-92 N•m 50-68 lb ft 128-148 N•m 94-109 lb ft Front Bumper Center Bolts 88-98 N•m 65-72 lb ft Front Bumper End Cap Bolts 88-98 N•m 65-72 lb ft Front Bumper End Cap Brace Bolts 20 N•m 15 lb ft Radiator Grille Brush Guard Bolts 20 N•m 15 lb ft Rear Bumper Bolts 97 N•m 72 lb ft Rear Bumper Bracket Lower Bolts 155 N•m 114 lb ft Rear Bumper Bracket Side
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8-18 Bumpers Body and Accessories BLANK 2006 LSSV Service Manual Supplement
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Body and Accessories Bumpers 8-19 Repair Instructions Center Radiator Grille Brush Guard Replacement Removal Procedure 1. Remove the blackout (B/O) headlamp. Refer to Headlamp Replacement – Blackout (B/O) (LSSV) in Lighting Systems. 2. Remove the slave receptacle. Refer to Slave Receptacle Replacement (LSSV) in Engine Electrical. 3. Remove the bolts (1) retaining the center brush guard to the bumper. 4. Remove the center brush guard from the vehicle. Installation Procedure 1.
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8-20 Bumpers Body and Accessories Installation Procedure 1. Install the center brush guard end to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts (1) retaining the brush guard to the vehicle. Tighten Tighten the bolts to 20 N•m (15 lb ft). 3. Install the center brush guard. Refer to Center Radiator Grille Brush Guard Replacement. Center Front Bumper Replacement Removal Procedure 1. Remove the D-Rings.
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Body and Accessories Bumpers 8-21 Bumper End Cap Replacement – Front Removal Procedure 1. Remove the center brush guard. Refer to Center Radiator Grille Brush Guard Replacement. 2. Remove the brush guard end. Refer to Outer Radiator Grille Brush Guard Replacement. 3. Remove the bolts (1) from the end cap brace. If the right side is being removed the ground cable must also be removed. 4. Remove the blackout (B/O) marker lamp. Refer to Marker Lamp Replacement – Front Blackout (B/O) (LSSV). 5.
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8-22 Bumpers Body and Accessories 3. Install the bolts (1) to the end cap brace. If the right side is being installed the ground cable must also be installed. Tighten Tighten the bolts to 20 N•m (15 lb ft). 4. Install the blackout (B/O) marker lamp. Refer to Marker Lamp Replacement – Front Blackout (B/O) (LSSV). 5. Install the brush guard end. Refer to Outer Radiator Grille Brush Guard Replacement. 6. Install the center brush guard. Refer to Center Radiator Grille Brush Guard Replacement.
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Body and Accessories Installation Procedure Bumpers 8-23 1. Install the front bumper bracket onto the frame. 2. Install the side and lower bolts, do not tighten at this time. 3. Install the center bumper (4). Refer to Center Front Bumper Replacement. 4. Install the bumper end cap (3). Refer to Bumper End Cap Replacement – Front. 5. Install the end brush guard (1). Refer to Outer Radiator Grille Brush Guard Replacement. 6. Install the center brush guard (2).
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8-24 Bumpers Body and Accessories Installation Procedure 1. Install the step onto the bumper. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the upper mounting bolts (1). Tighten Tighten upper bolts to 45 N•m (33 lb ft). 3. Install the lower mounting bolts (2). Tighten Tighten lower bolts to 45 N•m (33 lb ft). License Plate Bracket Replacement Removal Procedure 1. 2. 3. 4. Remove the retention pin (1) and pivot the bracket down. Remove the pivot bolt (2) and washer from the bracket.
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Body and Accessories Bumpers 8-25 Bracket Replacement – Rear Bumper (LSSV) Removal Procedure Caution: Refer to Vehicle Lifting Caution in Cautions and Notices. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information of the 2006 C/K Truck Service Manual. 2. Remove the rear D-ring (2) from the appropriate side. Refer to Rear D-Ring Bracket Replacement (LSSV) in Frame and Underbody. 3. Remove the bumper bolts (1). 4.
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8-26 Bumpers Body and Accessories 3. Install the bumper bolts (1). Tighten Tighten bumper bolts to 97 N•m (72 lb ft). 4. Install the rear D-ring (2) from the appropriate side. Refer to Rear D-Ring Bracket Replacement (LSSV) in Frame and Underbody. 5. Remove the supports and lower the vehicle. Bumper Replacement – Rear (LSSV) Removal Procedure 1. Remove the swing away spare tire carrier pivot bracket (4) (if equipped). Refer to Spare Tire Carrier Pivot Bracket Replacement (Swing Away) in Tires and Wheels.
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Body and Accessories Bumpers 8-27 8. Remove the 24V trailer connector (3). Refer to Military Trailer Connector Replacement (LSSV) in Lighting Systems. 9. Remove the 12V trailer connector (1). Refer to Commercial Trailer Connector Replacement (LSSV) in Lighting Systems. 10. Remove the rear winch power disconnect (2) (if equipped). Refer to Rear Winch Harness and Connector Replacement (LSSV) in Engine Electrical. 11. Remove the rear relay mounting bracket from the bumper. 12.
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8-28 Bumpers Body and Accessories 5. Install the rear winch power disconnect (2) (if equipped). Refer to Rear Winch Harness and Connector Replacement (LSSV) in Engine Electrical. 6. Install the 12V trailer connector (1). Refer to Commercial Trailer Connector Replacement (LSSV) in Lighting Systems. 7. Install the 24V trailer connector (3). Refer to Military Trailer Connector Replacement (LSSV) in Lighting Systems. 8. Install the license plate bracket (1). Refer to License Plate Bracket Replacement. 9.
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Body and Accessories Exterior Trim 8-29 Exterior Trim Specifications Fastener Tightening Specifications Specification Application Metric English Mud Flap Guard Brace Bolts 25 N•m 18 lb ft Mud Flap Guard Screws 4 N•m 35 lb in 2006 LSSV Service Manual Supplement
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8-30 Exterior Trim Body and Accessories BLANK 2006 LSSV Service Manual Supplement
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Body and Accessories Exterior Trim 8-31 Repair Instructions Mud Guard – Rear (One or Both) Replacement Removal Procedure Caution: Refer to Vehicle Lifting Caution in Cautions and Notices. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in 2006 C/K Truck Service Manual. 2. Remove the brace bolt (3). 3. Remove the plastic retainer (1). 4. Remove the screws (2). 5. Remove the mud guard (4) from the vehicle. Installation Procedure 1.
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8-32 Exterior Trim Description and Operation Exterior Trim Description Mud Guards These vehicles may be equipped with mud guards at the back of the rear wheel openings to prevent brake damage when exposed to off road conditions.
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Body and Accessories Frame and Underbody 8-33 Frame and Underbody Specifications Fastener Tightening Specifications Specification Application Metric English Body Mount Bolt 70 N•m 52 lb ft Center Support Beam Bracket Bolts (Pass Through) 35 N•m 26 lb ft Center Support Beam Bracket Bolts (Threaded Hole) 50 N•m 37 lb ft 87-97 N•m 64-72 lb ft Front Fuel Tank Skid Plate Bolts 50 N•m 37 lb ft Front Outer Fuel Tank Skid Plate Bolts 29 N•m 21 lb ft Front Skid Plate Bolts (Front) 20 N•m 15 l
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8-34 Frame and Underbody Body and Accessories BLANK 2006 LSSV Service Manual Supplement
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Body and Accessories Frame and Underbody 8-35 Repair Instructions Front Pull Winch Receiver Replacement Removal Procedure 1. Remove the center bumper. Refer to Center Front Bumper Replacement in Bumpers. 2. Remove the bolts (1) and remove the receiver by lifting up. Installation Procedure 1. Install the receiver into the brackets by pushing down. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the receiver bolts (1). Tighten Tighten receiver bolts to 88-98 N•m (65-72 lb ft). 3.
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8-36 Frame and Underbody Body and Accessories Installation Procedure Important: The flat side of the D-ring must be facing out. 1. Install the D-ring on the bracket. 2. Slide the new wave washer (1) between the D-ring and the bracket. 3. Install the D-ring nut and bolt (2). Tighten the nut and bolt until the D-ring will stand straight out on its own. Rear D-Ring Replacement (LSSV) Removal Procedure 1. Remove the nut and bolt (1). 2. Remove the D-ring from the mount. 3. Discard the wave washer (2).
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Body and Accessories Frame and Underbody 8-37 Front D-Ring Bracket Replacement Removal Procedure 1. Remove the D-ring. Refer to Front D-Ring Replacement (LSSV). 2. Remove the D-ring mounting bracket bolts (1). 3. Remove the D-ring bracket. Installation Procedure 1. Install the D-ring bracket to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the D-ring mounting bracket bolts. Tighten Tighten the bolts to 87-97 N•m (64-72 lb ft). 3. Install the D-ring.
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8-38 Frame and Underbody Body and Accessories Installation Procedure 1. Install the D-ring bracket to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the D-ring mounting bracket bolts (1). Tighten Tighten the bolts to 97 N•m (72 lb ft). 3. Install the D-ring. Refer to Rear D-Ring Replacement (LSSV) Upper Radiator Support Reinforcement Removal Procedure Caution: Refer to Vehicle Lifting Caution in Cautions and Notices.
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Body and Accessories Frame and Underbody 8-39 Lower Radiator Support Reinforcement Removal Procedure Caution: Refer to Vehicle Lifting Caution in Cautions and Notices. Important: Ensure that the vehicle is unloaded prior to reinforcement replacement. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in 2006 C/K Truck Service Manual. 2. Loosen the other body mount nuts. 3. Properly support the body in the area that the mounts will be replaced. 4.
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8-40 Frame and Underbody Body and Accessories Installation Procedure 1. Install the skid plate (2) to the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the rear bolts (3). Tighten Tighten the bolts to 35 N•m (26 lb ft). 3. Install the front bolts (1). Tighten Tighten the bolts to 20 N•m (15 lb ft). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in 2006 C/K Truck Service Manual.
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Body and Accessories Frame and Underbody 8-41 Front Support Beam Replacement Removal Procedure Caution: Refer to Vehicle Lifting Caution in Cautions and Notices. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in the 2006 C/K Truck Service Manual. 2. Remove the front skid plate. Refer to Front Skid Plate Replacement. 3. Remove the bolts (1) and nuts (2). 4. Remove the support beam (3) and (4). Installation Procedure 1. Install the support beam (3) and (4).
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8-42 Frame and Underbody Body and Accessories Installation Procedure 1. Install the brackets (1, 2) and (6) on the vehicle. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts (3, 4) and (5) and nuts (7). Tighten • Tighten bolts (3, 4) to 35 N•m (26 lb ft). 3. 4. 5. 6. • Tighten bolts (5) to 50 N•m (37 lb ft). Install the front support beams. Refer to Front Support Beam Replacement. Install the rear support beams. Refer to Rear Support Beam Replacement.
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Body and Accessories Frame and Underbody 8-43 Rear Frame Bracket Replacement Removal Procedure Caution: Refer to Vehicle Lifting Caution in Cautions and Notices. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in the 2006 C/K Truck Service Manual. 2. Remove the rear skid plate. Refer to Rear Skid Plate Replacement. 3. Remove the rear support beam. Refer to Rear Support Beam Replacement. 4. Remove the nuts (3) and bolt (1). 5. Remove the rear mounts (2) and (4).
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8-44 Frame and Underbody Body and Accessories 5. Remove the outer front cover bolts (1) from the support (2). 6. Remove the cover bolts (1), remove support and lower the cover (2). Remove from the vehicle. Installation Procedure 1. Install the cover and support. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the cover bolts (1). Tighten Tighten bolt to 29 N•m (21 lb ft). 3. Install the front cover bolts (2). Tighten Tighten bolts to 50 N•m (37 lb ft).
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Body and Accessories Frame and Underbody 8-45 4. Install the upper cover bolt. Tighten Tighten bolts to 85 N•m (63 lb ft). 5. Install the outer front bolts (1). Tighten Tighten bolts to 50 N•m (37 lb ft). 6. Remove fuel tank support. 7. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in 2006 C/K Truck Service Manual.
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8-46 Frame and Underbody Body and Accessories BLANK 2006 LSSV Service Manual Supplement
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Body and Accessories Horns 8-47 Horns Schematic and Routing Diagrams 2006 LSSV Service Manual Supplement
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Horn Schematics 8-48 Horns 2006 LSSV Service Manual Supplement Body and Accessories
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Body and Accessories Horns 8-49 Diagnostic Information and Procedures Symptoms – Horns Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: • Horns Inoperative in Blackout (B/O) Mode • Horns Operate In Blackout (B/O) Mode Horns Inoperative in Blackout (B/O) Mode Step Action Yes No Go to Step 2 Go to Horn with Blackout (B/O) Control Circuit Operation Go to Horns Inoperative – One Horn 2006 C/K Truck Service Manual Go to Step 3 Go to Step 4 Go to Hor
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8-50 Horns Body and Accessories Horns Inoperative in Blackout (B/O) Mode (cont’d) Step 11 Action Replace the blackout (B/O) service light switch. Refer to Blackout (B/O) Switch Replacement in Lighting Systems. Did you complete the replacement? 12 13 Yes ___ Go to Step 13 Repair the open or high resistance in the (OG) circuit 40. Did you complete the repair? No Go to Step 13 ___ Verify the system operation.
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Body and Accessories Horns 8-51 Description and Operation Horn with Blackout (B/O) Control Circuit Operation Voltage is applied at all times to the horn relay through the 15A horn fuse in the underhood fuse block. The blackout (B/O) service drive switch is used to control the horn relay. Power is applied through OG (circuit 40) to the blackout (B/O) service drive switch, which is normally a closed switch.
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8-52 Horns Body and Accessories BLANK 2006 LSSV Service Manual Supplement
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Body and Accessories Instrument Panel, Gages, and Console 8-53 Instrument Panel, Gages, and Console Specifications Fastener Tightening Specifications Specification Application Accessory Instrument Panel (I/P) Bolts Voltmeter Gage Nuts Metric English 8 N•m 71 lb in 2.
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Instrument Cluster Schematics (Voltmeter Gage) 8-54 Instrument Panel, Gages, and Console 2006 LSSV Service Manual Supplement Body and Accessories
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Body and Accessories Instrument Panel, Gages, and Console 8-55 Component Locator Instrument Panel, Gages, and Console Component Views Front Side of the Instrument Panel Legend (1) Tire Pressure Monitoring System Gage (4) Air Filter Restriction Gage (2) Tire Pressure Monitoring System Switch Panel (5) Fiberglass Cap Dome Lamp Switch (3) 24 Voltmeter Gage (6) Blackout (B/O) Lighting Switches 2006 LSSV Service Manual Supplement
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8-56 Instrument Panel, Gages, and Console Instrument Panel, Gages, and Console Connector End Views Voltmeter Gage Connector Part Information • 02973781 • 2-Way F 56 Series (BK) Wire Color Circuit No.
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Body and Accessories Instrument Panel, Gages, and Console 8-57 • Diagnostic Information and Procedures Symptoms – Instrument Panel, Gages and Console Important: The following steps must be completed before using the symptom tables. Review the system operation in order to familiarize yourself with the system function. Refer to Charging System Description and Operation in Engine Electrical.
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8-58 Instrument Panel, Gages, and Console BLANK 2006 LSSV Service Manual Supplement Body and Accessories
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Body and Accessories Instrument Panel, Gages, and Console 8-59 Repair Instructions Voltmeter Gage Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the battery cables. Refer to Battery Cable Disconnect/Connect Procedure in Engine Electrical. 2. Remove the accessory panel. Refer to Accessory Instrument Panel (I/P) Replacement. 3. Remove the nuts (4) from the back of the voltmeter. 4. Remove the voltmeter connector (2). 5.
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8-60 Instrument Panel, Gages, and Console Body and Accessories 4. Disconnect the voltmeter gage bulb and harness connectors (3) from the gage. 5. Disconnect the blackout (B/O) harness connectors (1) from the switches. 6. Disconnect the air line (2) from the air filter restriction gage (if equipped). 7. Remove the panel (4) from the vehicle. 8. Remove the parts from the accessory panel.
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Body and Accessories Instrument Panel, Gages, and Console 8-61 Air Filter Restriction Gage Replacement Removal Procedure 1. Remove the accessory panel. Refer to Accessory Instrument Panel (I/P) Replacement. 2. Remove the air line (2) from the gage (1). 3. Remove the screws (1) that retain the gage (2) to the accessory panel. 4. Remove the gage from the accessory panel. Installation Procedure 1. Install the gage to the accessory panel. 2.
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8-62 Instrument Panel, Gages, and Console Body and Accessories 3. Install the air line (2) to the gage (1). 4. Install the accessory panel. Refer to Accessory Instrument Panel (I/P) Replacement. Air Filter Restriction Gage Hose Replacement Removal Procedure Note routing position prior to removal of line for installation. 1. Remove the gage hose (2) from the line adaptor (3). 2. Remove the line from the clip (1). 3. Remove the lower bolts (1) of the accessory panel (2). 4.
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Body and Accessories Instrument Panel, Gages, and Console 8-63 5. Remove panel enough to gain access to the air line (2). 6. Remove the air line (2) from the flow gage (1). 7. Remove the airflow line grommet (1) from the bulkhead and remove air line (2) from the vehicle. Installation Procedure 1. Install the air line (2) with the grommet (1) and secure the grommet into the bulkhead opening.
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8-64 Instrument Panel, Gages, and Console Body and Accessories 2. Route the air line through the I/P in the same location as removed. 3. Install the air line (2) onto the flow gage (1). Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the accessory panel (2) onto the I/P and install bolts (1). Tighten Tighten bolts to 8 N•m (71 lb in). 5. Push the I/P cluster bezel back in place over the panel. 6. Route the air line (2) through the engine compartment as removed. 7.
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Body and Accessories Instrument Panel, Gages, and Console 8-65 Air Filter Restriction Gage Adapter Replacement Removal Procedure 1. Remove the air line (2) from the adapter (3). 2. Remove the adapter (3) from the air cleaner housing grommet. Installation Procedure 1. Install the adapter (3) into the air cleaner housing grommet until fully seated. 2. Install the air line (2) onto the adapter (3).
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8-66 Instrument Panel, Gages, and Console Description and Operation Instrument Panel (I/P) Gages Description The instrument panel has been modified with an accessory panel mounted below the accessory power outlets. This panel houses the blackout (B/O) lighting auxiliary switches, 24V voltmeter gage and a air filter restriction gage (if equipped). The instrument panel houses auxiliary harnesses as well as standard indicators.
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Body and Accessories Interior Trim 8-67 Interior Trim Specifications Fastener Tightening Specifications Specification Application Metric English Cab Mount Gun Rack Bolts – Lower 3.
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8-68 Interior Trim Body and Accessories BLANK 2006 LSSV Service Manual Supplement
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Body and Accessories Interior Trim 8-69 Repair Instructions Government Vehicle Data Plate Replacement Removal Procedure 1. Drill out the 4 rivets (3). 2. Remove the data plate (2). Installation Procedure 1. Install the plate (2) to the original holes. 2. Install the new rivets (3). Shipping Data Plate Replacement Removal Procedure 1. Drill out the 4 rivets (3). 2. Remove the data plate (1).
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8-70 Interior Trim Body and Accessories Installation Procedure 1. Install the plate (1) to the original holes. 2. Install the new rivets (3). Floor Mat Replacement Removal Procedure 1. Remove bolts securing gun rack (1) and remove mount. Refer to Floor Mount Gun Rack Replacement or Lower Cab Mount Gun Rack Replacement. 2. Remove floor mat. Refer to Carpet Replacement – Front in Interior Trim in the 2006 C/K Truck Service Manual.
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Body and Accessories Installation Procedure Interior Trim 8-71 1. Using the old floor mat as a template cut gun rack holes in the new floor mat. 2. Install the floor mat. Refer to Carpet Replacement – Front in Interior Trim in the 2006 C/K Truck Service Manual. 3. Install gun rack (1) and install bolts. Refer to Floor Mount Gun Rack Replacement or Lower Cab Mount Gun Rack Replacement. Floor Mount Gun Rack Replacement Removal Procedure 1. Remove the rear nut securing gun rack to the floor. 2.
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8-72 Interior Trim Body and Accessories Installation Procedure 1. Install the gun rack (1) and slide under the front seat bolts. 2. Align the rear gun rack hole with stud in the floor. Notice: Refer to Fastener Notice in Cautions and Notices. 3. Install the nut on the stud and tighten. Tighten • Tighten the rear nut to 20 N•m (15 lb ft). • Tighten the front bolts to 55 N•m (41 lb ft). Lower Cab Mount Gun Rack Replacement Removal Procedure 1. Remove the 2 bolts (1) holding the support to the floor. 2.
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Body and Accessories Interior Trim 8-73 Upper Cab Mount Gun Rack Replacement Removal Procedure 1. Remove the lower rear window molding. Refer to Molding Replacement – Rear Window Lower in Interior Trim in the 2006 C/K Truck Service Manual. 2. Remove the bolts (1) holding the upper mount to the inner body. 3. Remove the upper gun rack (2). Installation Procedure 1. Install the upper gun rack assembly (2) by aligning to the body side inner upper panel.
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8-74 Interior Trim Body and Accessories Installation Procedure 1. Install the left bracket (2) or the right bracket (3). Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the 4 bolts (1) to the bracket. Tighten Tighten the bolts to 8 N•m (70 lb in). 3. Install the lower rear window molding. Refer to Molding Replacement – Rear Window Lower in Interior Trim in the 2006 C/K Truck Service Manual. 4. Install the pioneer tool kit.
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Body and Accessories Interior Trim 8-75 Enhanced Mobility Package Jack Mounting Bracket Replacement (Regular Cab) Removal Procedure 1. 2. 3. 4. Slide the front seat to the forward position. Remove the vehicle jack from the bracket. Remove the bracket fasteners (1). Remove the mounting bracket. Installation Procedure 1. Install the mount bracket in the mounting position. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bracket fasteners (1).
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8-76 Interior Trim Body and Accessories Installation Procedure 1. Install the mount bracket in the mounting position. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts (1) into the rivnut. Tighten Tighten the bolt to 9 N•m (80 lb in). 3. Install the nuts (2) onto the stud. Tighten Tighten the nut to 13 N•m (10 lb ft). 4. Install the vehicle jack in the bracket. 5. Lower the rear seat. Enhanced Mobility Package Jack Mounting Bracket Replacement (Crew Cab) Removal Procedure 1.
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Body and Accessories Interior Trim 8-77 Enhanced Mobility Package Jack Tools Mounting Bracket Replacement Removal Procedure 1. Remove the jack tools from the brackets. 2. Remove the bracket nuts (1). 3. Remove the mounting brackets. Installation Procedure 1. Install the mount bracket in the mounting position. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the bracket nuts (1) securing the brackets to the vehicle. Tighten Tighten the bolt to 9 N•m (80 lb in). 3.
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8-78 Interior Trim Body and Accessories BLANK 2006 LSSV Service Manual Supplement
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Body and Accessories Lighting Systems 8-79 Lighting Systems Specifications Fastener Tightening Specifications Specification Application Metric English Blackout (B/O) Headlamp Stud Nut 10 N•m 89 lb in Blackout (B/O) Switch Nuts 2.8 N•m 24 lb in 2 N•m 18 lb in 0.
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Exterior Lights Schematics (Blackout (B/O) Relay Block) 8-80 Lighting Systems 2006 LSSV Service Manual Supplement Body and Accessories
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Lighting Systems 8-81 Exterior Lights Schematics (Interrupt Relays (I/P Fuse Block)) Body and Accessories 2006 LSSV Service Manual Supplement
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Exterior Lights Schematics (Blackout (B/O) Light Controls) 8-82 Lighting Systems 2006 LSSV Service Manual Supplement Body and Accessories
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Lighting Systems 8-83 Exterior Lights Schematics (Exterior Lighting) Body and Accessories 2006 LSSV Service Manual Supplement
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Exterior Lights Schematics (Trailer Wiring) 8-84 Lighting Systems 2006 LSSV Service Manual Supplement Body and Accessories
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Lighting Systems 8-85 Exterior Lights Schematics (Rear Relay Harness) Body and Accessories 2006 LSSV Service Manual Supplement
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Interior Lights Schematics (Topper Wiring) 8-86 Lighting Systems 2006 LSSV Service Manual Supplement Body and Accessories
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Lighting Systems 8-87 Interior Lights Dimming Schematics Body and Accessories 2006 LSSV Service Manual Supplement
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8-88 Lighting Systems Body and Accessories Component Locator Lighting Systems Component Views Front Lighting – LSSV Legend (1) Blackout (B/O) Marker Lamps 2006 LSSV Service Manual Supplement (2) Blackout (B/O) Headlamp
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Body and Accessories Lighting Systems 8-89 Rear Lighting – LSSV Legend (1) Blackout (B/O) Marker/Stoplamps (3) Trailer Connector (NATO 12 Pin) (2) Trailer Connector (Commercial) (4) License Plate Lamp 2006 LSSV Service Manual Supplement
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8-90 Lighting Systems Body and Accessories Blackout (B/O) Drive Relay Lighting Systems Connector End Views Blackout (B/O) Drive Lamp Switch Connector Part Information Connector Part Information • 08911352 • 5-Way F Series 56 (BK) Pin Wire Color Circuit No. Function A — — B TN/WH 901 Blackout (B/O) Headlamp C PK 911 Supply Voltage D WH 915 Blackout (B/O) E BK 150 Drive Lamp Switch • 12129716 • 4-Way F M/P Series 280 (GY) Pin Wire Color Circuit No.
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Body and Accessories Blackout (B/O) Lamps Fuse Connector Part Information Pin A B • 12010105 • 2-Way M (BK) Wire Color Circuit No. BN/WH 900 PK 911 Lighting Systems 8-91 Blackout (B/O) Lamps (Right Rear) Connector Part Information • 12010973 • 2-Way M Weather Pack (BK) Function Pin Circuit No.
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8-92 Lighting Systems Body and Accessories Blackout (B/O) Service Switch Connector Part Information Pin A • 08917695 • 6-Way F Series 58 (BK) Wire Color Circuit No.
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Body and Accessories Trailer Lamp Connector Connector Part Information • 08917884 • 12-Way Weather Pack (BK) Lighting Systems 8-93 Topper Dome Lamp Switch Connector (Accessory Panel) Connector Part Information Function • 02965114 • 3-Way F 56 Series Unsealed (BK) Pin Wire Color Circuit No. A BN 900 Blackout (B/O) Marker Lamps Pin Wire Color Circuit No.
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8-94 Lighting Systems Body and Accessories Voltmeter Gage Lamp Connector Part Information • 12004264 • 2F LP SOC Hardshell (BK) Pin Wire Color Circuit No.
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Body and Accessories Lighting Systems 8-95 Diagnostic Information and Procedures Symptoms – Lighting Systems Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: • Blackout (B/O) Headlamp Inoperative • Blackout (B/O) Headlamp Always On • Headlamps Operate in Blackout (B/O) Mode • Blackout (B/O) Stoplamps Inoperative • Blackout (B/O) Marker Lamps Inoperative • Voltmeter Gage Lamp Inoperative • Blackout (B/O) Marker Lamps Always On • D
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8-96 Lighting Systems Body and Accessories Blackout (B/O) Headlamp Inoperative (cont’d) Step 8 Action Locate and repair open in circuit 901 (TN/WH) wire between blackout (B/O) lamp cavity A and blackout (B/O) drive relay cavity 85. Did you complete the repair? 9 14 Go to Step 10 Go to Step 11 Go to Step 13 Go to Step 15 Go to Step 12 Go to Step 14 Locate and repair open in circuit 911 (PK) between blackout (B/O) service lamp switch and blackout (B/O) drive relay.
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Body and Accessories Lighting Systems 8-97 Blackout (B/O) Headlamp Always On Step Action Yes No Schematic Reference: Exterior Lights Schematics and Interior Lights Schematics 1 2 Did you review Blackout (B/O) Lighting Description and Operation? ___ Go to Step 5 Repair short to power in circuit 901 (TN/WH) or inoperable blackout (B/O) control relay. Did you find and correct the condition? 5 Go to Step 4 Replace blackout (B/O) drive lamp switch. Refer to Blackout (B/O) Switch Replacement.
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8-98 Lighting Systems Body and Accessories Blackout (B/O) Stoplamps Inoperative Step Action Yes No Schematic Reference: Exterior Lights Schematics and Interior Lights Schematics 1 Did you review Blackout (B/O) Lighting Description and Operation? Observe the stoplamps while pressing the brake pedal.
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Body and Accessories Lighting Systems 8-99 Blackout (B/O) Stoplamps Inoperative (cont’d) Step 14 Action Replace the blackout (B/O) stoplamp(s). Refer to Taillamp/Blackout (B/O) Lamp Replacement. Did you complete the replacement? 15 Yes No ___ Go to Step 15 Operate the system in order to verify the repair.
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8-100 Lighting Systems Body and Accessories Blackout (B/O) Marker Lamps Inoperative (cont’d) Step 10 Action Locate and repair an open in circuit 911 (PK) wire between inline fuse B and blackout (B/O) service drive switch. Did you complete the repair? 11 13 Go to Step 12 Replace blackout (B/O) marker lamp(s) assembly.
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Body and Accessories Lighting Systems 8-101 Voltmeter Gage Lamp Inoperative (cont’d) Step Action 2 Connect a test lamp between cavity A of the voltmeter bulb and ground. Does the test lamp illuminate? 3 4 5 7 No Go to Step 3 Go to Step 4 Go to Step 5 Go to Step 6 Connect a self-powered test lamp to cavity B and ground. Does the test lamp illuminate? Locate and repair the open or high resistance in circuit 9. Did you complete the repair? Go to Step 7 Replace the voltmeter gage bulb.
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8-102 Lighting Systems Body and Accessories DRL Operate in Blackout (B/O) Mode Step Action Yes No Schematic Reference: Exterior Lights Schematics and Interior Lights Schematics 1 Did you review Blackout (B/O) Lighting Description and Operation? Go to Step 2 Go to Blackout (B/O) Lighting Circuit Operation Go to Step 3 Go to Step 6 Go to Step 5 Go to Step 4 1. Place the blackout (B/O) service switch in blackout (B/O) mode. 2 2.
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Body and Accessories Lighting Systems 8-103 Backup Lamps Inoperative (cont’d) Step Action Yes No Go to Step 17 Go to Step 6 Go to Step 17 Go to Step 13 Go to Step 7 Go to Step 9 Go to Step 8 Go to Step 13 1. Inspect the condition of the backup lamp fuses. 4 5 2. If the fuse is open, locate and repair the source of the overload and replace fuse. Test the ground circuit of the inoperative bulb for high resistance or an open.
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8-104 Lighting Systems Body and Accessories Backup Lamps Operate in Blackout (B/O) Mode Step Action Yes No Schematic Reference: Exterior Lights Schematics and Interior Lights Schematics 1 Did you review Blackout (B/O) Lighting Description and Operation? Go to Step 2 Go to Blackout (B/O) Lighting Circuit Operation Go to Step 3 Go to Step 6 Go to Step 5 Go to Step 4 1. Place the blackout (B/O) service switch in blackout (B/O) mode. 2 2.
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Body and Accessories Lighting Systems 8-105 Park Lamps Operate in Blackout (B/O) Mode (cont’d) Step Action Yes No Go to Step 5 Go to Step 4 1. Disconnect the blackout (B/O) service switch connector from the switch. 3 2. Connect a test lamp at cavity C of the connector and ground. Does the test lamp illuminate? 4 Replace the blackout (B/O) service switch. Refer to Blackout (B/O) Switch Replacement.
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8-106 Lighting Systems Body and Accessories CTSY Lamps Operate in Blackout (B/O) Mode (cont’d) Step 6 7 8 9 Action Yes No Go to Step 8 Go to Step 7 Remove the CTSY 1 interrupt relay from the relay module. Are the CTSY lamps illuminated? Replace the CTSY 1 interrupt relay. Did you complete the replacement? Go to Step 9 Locate and repair the short to voltage on circuit 690 (GY/BK). Did you complete the repair? Go to Step 9 ___ ___ Operate the system in order to verify the repair.
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Body and Accessories Lighting Systems 8-107 High Beam Headlamps Operate in Blackout (B/O) Mode Step Action Yes No Schematic Reference: Exterior Lights Schematics and Interior Lights Schematics 1 Did you review Blackout (B/O) Lighting Description and Operation? Go to Step 2 Go to Blackout (B/O) Lighting Circuit Operation Go to Step 3 Go to Step 6 Go to Step 5 Go to Step 4 1. Place the blackout (B/O) service switch in blackout (B/O) mode. 2 2.
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8-108 Lighting Systems Body and Accessories Low Beam Headlamps Operate in Blackout (B/O) Mode (cont’d) Step Action Yes No Go to Step 5 Go to Step 4 1. Disconnect the blackout (B/O) service switch connector from the switch. 3 2. Connect a test lamp at cavity C of the connector and ground. Does the test lamp illuminate? 4 Replace the blackout (B/O) service switch. Refer to Blackout (B/O) Switch Replacement.
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Body and Accessories Lighting Systems 8-109 Repair Instructions Topper Dome Lamp Switch Replacement – Front Removal Procedure Caution: Refer to Battery Disconnect Caution in Caution and Notices. 1. Disconnect the battery cables. Refer to Battery Cable Disconnect/Connect Procedure in Engine Electrical. 2. Remove the accessory panel. Refer to Accessory Instrument Panel (I/P) Replacement in Instrument Panel, Gages and Console. 3. Remove the nut (2) and washer (3) from the switch. 4.
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8-110 Lighting Systems Body and Accessories Installation Procedure 1. 2. 3. 4. Install the switch (1) into the vehicle. From inside the cargo area install the nut onto the switch. Install the connector (2) onto the switch. Install the left rear tail/turn signal lamp. Refer to Tail/Turn Signal Lamp Replacement (Except Stepside) in Lighting Systems in 2006 C/K Truck Service Manual. Blackout (B/O) Switch Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices. 1.
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Body and Accessories Lighting Systems 8-111 Commercial Trailer Connector Replacement (LSSV) Removal Procedure 1. Ensure that all lamp switches are in the OFF position. 2. Disconnect the harness connector from the trailer connectors. 3. Release the lock tabs, turn the trailer connector (1) and pull out from the bumper. Installation Procedure 1. Install the trailer connector (1) into the opening in bumper. 2. Turn the connector until lock tabs engage. 3.
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8-112 Lighting Systems Body and Accessories Installation Procedure Important: The cover hinge must be installed at the 9 O’clock position. 1. Install the trailer connector (2) and cover (3) onto the bumper. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the fasteners to secure the cover and connector to the bumper. Tighten Tighten the connector bolts to 5 N•m (44 lb in). 3. Connect the harness connectors (1). Headlamp Replacement – Blackout (B/O) (LSSV) Removal Procedure 1.
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Body and Accessories Lighting Systems 8-113 Headlamp Bulb Replacement – Blackout (B/O) Removal Procedure 1. Remove the screws (1) holding the lens cap to the assembly. 2. Remove the lens cap (2) and O-ring. 3. Remove the bulb from the lamp socket. Installation Procedure Important: Use a standard 1073 bulb for replacement. 1. Install the new bulb in the lamp socket. Important: The O-ring installation must be a proper fit. 2. Install the O-ring with the lens cap (2). 3.
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8-114 Lighting Systems Body and Accessories 5. Remove the blackout (B/O) marker lamp assembly (1) from the bumper. Installation Procedure 1. Install the marker lamp (1) into the front bumper opening. Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the nuts (1) and the ground connector (2) onto the maker lamp studs. Tighten Tighten the marker lamp nuts to 2 N•m (18 lb in). 3. Install the harness connector (3) to the marker lamp connector. 4.
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Body and Accessories Lighting Systems 8-115 Blackout (B/O) Taillamp Replacement (LSSV) Removal Procedure 1. Ensure all lamp switches are in the OFF position. 2. Remove the wiring harness strap from the taillamp harness. 3. Disconnect the taillamp harness connector (1) by releasing the tab. 4. Remove the nuts (2) and the ground connector (3) from the rear of the bumper. 5. Remove the taillamp (1) from the bumper. Installation Procedure 1. Position the taillamp (1) onto the bumper.
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8-116 Lighting Systems Body and Accessories Notice: Refer to Fastener Notice in Cautions and Notices. 2. Install the nuts (2) and the ground connector (3) onto the mounting studs. Tighten Tighten the nuts to 2 N•m (18 lb in). 3. Connect the harness connector (1) to the taillamp connector. 4. Install the harness into the original mounting location using the wiring harness strap.
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Body and Accessories Lighting Systems 8-117 Voltmeter Gage Lamp Replacement Removal Procedure 1. Ensure all lamp switches are in the OFF position. 2. Remove the accessory panel. Refer to Accessory Instrument Panel (I/P) Replacement in Instrument Panel, Gages and Console. 3. Remove the voltmeter gage lamp socket from the back of the voltmeter gage. 4. Remove the bulb (1) from the voltmeter socket. Installation Procedure Important: Use a standard 194 bulb for replacement. 1.
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8-118 Lighting Systems Body and Accessories Installation Procedure 1. Connect the electrical wiring and install the lamp onto the topper. 2. Install the screws (1) and secure. 3. Install the topper dome lamp bulb. Refer to Topper Dome Lamp Bulb Replacement. Topper Dome Lamp Bulb Replacement Removal Procedure 1. Press in on the sides of the lens to release the lens tabs. 2. Remove the bulb from the lamp socket. Installation Procedure 1. Install the bulb into the lamp socket. 2.
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Body and Accessories Lighting Systems 8-119 Description and Operation is parked for over 24 hours, place the service switch in the ALL OFF position. Blackout (B/O) Lighting Circuit Operation To operate the blackout (B/O)/drive light switch pull it out and up to the ON position; this will activate the front blackout (B/O) headlamp. This will occur provided the service light/blackout (B/O) switch remains in the ON or down position.
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8-120 Lighting Systems Body and Accessories Function Tables The following are function tables for the service light/blackout (B/O) control switch and determines under what conditions various exterior and interior lighting functions activate.
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Body and Accessories Paint/Coatings 8-121 Paint/Coatings Specifications Paint Codes Exterior and Interior Colors Location/Color Fed.-std.-595 B PPG No.
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8-122 Paint/Coatings Body and Accessories BLANK 2006 LSSV Service Manual Supplement
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Body and Accessories Paint/Coatings 8-123 Repair Instructions Exterior Painting (LSSV) Metal Refinishing Caution: Refer to Eye Protection Caution in Cautions and Notices in 2006 C/K Truck Service Manual. 1. Remove all exterior ornaments and emblems from the panel to be painted. Important: Cut paint at door seals, remove or mask over door seals. 2. Prepare all metal surfaces to be painted. Important: This is not CARC (Chemical Agent Resistant Coating) paint. The recommended supplier is PPG. 3.
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8-124 Paint/Coatings Body and Accessories BLANK 2006 LSSV Service Manual Supplement
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Body and Accessories Seats 8-125 Seats Specifications Fastener Tightening Specifications Specification Application Seat Bolts – Troop Metric English 58 N•m 43 lb ft 2006 LSSV Service Manual Supplement
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8-126 Seats Body and Accessories BLANK 2006 LSSV Service Manual Supplement
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Body and Accessories Seats 8-127 Repair Instructions Seat Replacement – Troop Removal Procedure 1. Remove the 2 bolts, nuts and clamps holding the seat assembly to the box rail. Note the clamp and stud arrangement for installation later. 2. Fold the seat section to the seatback and install the tether pins to the locking holes for easy removal. 3. Remove the 2 bolts and Nylock nuts from the end of the rail. 4. Remove the troop seat assembly.
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8-128 Seats Description and Operation Folding Rear Seat – Troop The troop seats provide two benches with seating for up to four troops on each side. Each bench is anchored by three sets of fasteners to each box rail. The seats can be folded up using tether pins to afford more cargo space. They are equipped with a safety strap, which should be hooked across the rear end of the box when occupied. Refer to the 2006 LSSV Owners Manual Supplement for further details.
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Body and Accessories Wiring Systems 8-129 Wiring Systems Specifications Fastener Tightening Specifications Specification Application Fender Brace Bolts Metric English 25 N•m 18 lb ft Schematic and Routing Diagrams 2006 LSSV Service Manual Supplement
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Power Distribution Schematics (12V/24V) 8-130 Wiring Systems 2006 LSSV Service Manual Supplement Body and Accessories
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Wiring Systems 8-131 Power Distribution Schematics (24V – Trailer Fuse) Body and Accessories 2006 LSSV Service Manual Supplement
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Power Distribution Schematics (Relay Block) 8-132 Wiring Systems 2006 LSSV Service Manual Supplement Body and Accessories
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Wiring Systems 8-133 Ground Distribution Schematics (G100M, G101M, G102M, G103M, G301M) Body and Accessories 2006 LSSV Service Manual Supplement
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Ground Distribution Schematics (G105M) 8-134 Wiring Systems 2006 LSSV Service Manual Supplement Body and Accessories
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Wiring Systems 8-135 Ground Distribution Schematics (G304M) Body and Accessories 2006 LSSV Service Manual Supplement
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Ground Distribution Schematics (G901M) 8-136 Wiring Systems 2006 LSSV Service Manual Supplement Body and Accessories
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Wiring Systems 8-137 Ground Distribution Schematics (G902M, G903M and G904M) Body and Accessories 2006 LSSV Service Manual Supplement
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8-138 Wiring Systems Body and Accessories Harness Routing Views Forward Blackout (B/O) Lamp Harness Legend (1) Instrument Panel (I/P) Wiring Harness (4) C102M (2) Forward Lamp Harness (5) C101M (3) G100M (6) C100M 2006 LSSV Service Manual Supplement
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Body and Accessories Wiring Systems 8-139 Rear Lamp Extension Harness – LSSV Legend (1) C908M (3) I/P Wiring Harness (2) Auxiliary Rear Lamp Wiring Harness 2006 LSSV Service Manual Supplement
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8-140 Wiring Systems Body and Accessories Relay Block Harness Legend (1) Interrupt Relays (5) To Rear Extension Harness (2) To Front Blackout (B/O) Lamps (6) Ground Stud (3) To Ground Stud (7) Blackout (B/O) Panel Harness (4) To Engine Harness 2006 LSSV Service Manual Supplement
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Body and Accessories Wiring Systems 8-141 Rear Lamp Harness Legend (1) C902M (5) C908M (2) License Plate Lamp (6) C900M (3) Trailer Lighting Relays (7) C901M (4) C903M 2006 LSSV Service Manual Supplement
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8-142 Wiring Systems Body and Accessories Component Locator Master Electrical Component List Name 24V Slave Receptacle Assembly Location On the right side of the bumper brush guard 24 Voltmeter Gage Lamp Mounted in the accessory panel on the lower center of the I/P Backup Lamp Relay Inline on the interrupt harness under the I/P Blackout (B/O) Drive Relay Inline on the auxiliary I/P harness Blackout (B/O) Headlamp On the left side of the bumper brush guard Locator View Connector End View Engine El
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Body and Accessories Wiring Systems 8-143 Master Electrical Component List (cont’d) Name Generator Fuses – 24V Location Locator View Connector End View ___ Engine Electrical Connector End Views in Engine Electrical Engine Electrical Component Views in Engine Electrical ___ Interrupt relay block RH engine compartment Engine Electrical Component Views in Engine Electrical ___ RH of engine compartment on the underhood fuse block Engine Electrical Component Views in Engine Electrical ___ Left of
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8-144 Wiring Systems Body and Accessories Master Electrical Component List (cont’d) Name Location C302M (2 Cavities) Under I/P for brake lamps C304M (2 Cavities) Blackout (B/O) panel for voltmeter C305M (2 Cavities) Under I/P for CTSY interrupt C306M (1 Cavity) Under I/P for backup lamps C307M (7 Cavities) Under I/P Dimming Relay C308M (2 Cavities) Under I/P for blackout (B/O) switch C309M (1 Cavity) Engine compartment by underhood fuse block C900M (3 Cavities) Rear bumper for trailer con
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Body and Accessories Wiring Systems 8-145 Master Electrical Component List (cont’d) Name Location Locator View Connector End View G902M Right side of the rear bumper ___ ___ G903M Left side of the rear bumper ___ ___ G904M Around the rear topper dome lamp switch ___ ___ S100M In front bracket wiring harness behind front bumper ___ ___ S102M In the front blackout (B/O) harness at front bumper ___ ___ S104M In the 24V generator harness in the engine compartment ___ ___ S105M In
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8-146 Wiring Systems Body and Accessories Master Electrical Component List (cont’d) Name Location Locator View Connector End View S907M In the rear blackout (B/O) harness at the rear bumper ___ ___ S908M In the trailer harness at rear bumper ___ ___ S909M In the trailer harness at rear bumper ___ ___ 2006 LSSV Service Manual Supplement
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Body and Accessories Wiring Systems 8-147 Electrical Center Identification Views Relay Block – I/P Legend (1) Cavity C – Blackout (B/O) Switch (4) Cavity E – 24 Voltmeter Gage Ground (2) C8 – Connector Location (5) Cavity F – 24 Voltmeter Gage (3) C5 – Connector Location (6) Relay Block – I/P 2006 LSSV Service Manual Supplement
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8-148 Wiring Systems Body and Accessories Relay Block – I/P C5 Connector Part Information • 12193928 • 6-Way F Metri-Pack 280 Series Flexlock (GY) Pin Wire Color Circuit No. A ___ ___ PU/WH Function Connector Part Information • 12193930 • 6-Way F Metri-Pack 280 Series Flexlock (BK) Pin Wire Color Circuit No.
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Body and Accessories Wiring Systems 8-149 Underhood Relay Block – Blackout (B/O) Lighting Legend (1) Turn Signal Relay (5) Headlamp Low-Beam Relay (2) Park Lamp Relay (6) DRL Relay (3) Headlamp High Beam Relay (7) Horn Relay (4) Interrupt Wiring Harness 2006 LSSV Service Manual Supplement
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8-150 Wiring Systems Body and Accessories 24V Trailer Fuse Connector Part Information • 12010105 • 2-Way F Auto Fuse Holder Pin Wire Color Circuit No. A RD/BK 8009 RD/WH 802 B 24V Accessory Fuse Connector Part Information Function • 12010105 • 2-Way F Auto Fuse Holder Pin Wire Color Circuit No.
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Body and Accessories Wiring Systems 8-151 Inline Harness Connector End Views C100M Front Blackout (B/O) Harness to Blackout (B/O) Marker Lamp • Connector Part Information • 12015791 1-Way F Weather Pack (BK) Pin Wire Color Circuit No. A BN/WH 900 Function Blackout (B/O) Marker Lamp (RF) Supply Voltage Connector Part Information Pin Wire Color A BK • 12010996 • 1-Way M Weather Pack (BK) Circuit No.
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8-152 Wiring Systems Body and Accessories C102M Front Blackout (B/O) Harness to Blackout (B/O) Headlamp • Connector Part Information Pin Wire Color A BK • 12015791 1-Way F Weather Pack (BK) Circuit No. Function Blackout (B/O) Headlamp Supply Voltage ___ Connector Part Information • 12010996 • 1-Way M Weather Pack (BK) Pin Wire Color Circuit No.
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Body and Accessories Wiring Systems 8-153 C105M UBEC Harness to Relay Interrupt Harness • Connector Part Information 12129136 • 4-Way F Flex-Lock 280 Series (BK) Pin Wire Color Circuit No. A WH 1080 B BK/WH C D Connector Part Information • 12129135 • 4-Way M M/P 280 Series (BK) Pin Wire Color Circuit No.
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8-154 Wiring Systems Body and Accessories C107M I/P Harness to Relay Block Harness • Connector Part Information • 12015791 1-Way F Weather Pack (BK) Pin Wire Color Circuit No. A OG 912 Function Supply Voltage to Relay Module Connector Part Information • 12010996 • 1-Way M Weather Pack (BK) Pin Wire Color Circuit No.
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Body and Accessories Wiring Systems 8-155 C201M I/P Harness to Tire Pressure Monitoring System Harness • Connector Part Information 1201571 • 1-Way F Weather Pack (BK) Pin Wire Color Circuit No. A BN 9 Function Supply Voltage to TPMS Gage Dimming Connector Part Information • 12010996 • 1-Way M Weather Pack (BK) Pin Wire Color Circuit No.
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8-156 Wiring Systems Body and Accessories C302M Brake Switch Harness to I/P Harness • Connector Part Information • 12129081 2-Way F Flex-Lock 280 Series (BK) Pin Wire Color Circuit No. A WH 17 B ___ ___ Connector Part Information • 12129155 • 2-Way M M/P 280 Series (BK) Pin Wire Color Circuit No.
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Body and Accessories Wiring Systems 8-157 C305M MBEC Harness to Relay Interrupt Harness • Connector Part Information 12129081 • 2-Way F Flex-Lock 280 Series (BK) Connector Part Information • 12129155 • 2-Way M M/P 280 Series (BK) Pin Wire Color Circuit No. Function Pin Wire Color Circuit No.
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8-158 Wiring Systems Body and Accessories C307M TBC Harness to Relay Interrupt Harness Connector Part Information • 12065873 • 7-Way F M/P 100 Pin Wire Color Circuit No. 1 GY 1056 2 OG/BK 3 Connector Part Information • 12065874 • 7-Way M M/P 100 Pin Wire Color Circuit No.
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Body and Accessories Wiring Systems 8-159 C308M Relay Interrupt Harness to I/P Harness • Connector Part Information • 12129081 2-Way F Flex-Lock 280 Series (BK) Pin Wire Color Circuit No. A OG 912 B BK 150 Connector Part Information • 12129155 • 2-Way M M/P 280 Series (BK) Pin Wire Color Circuit No.
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8-160 Wiring Systems Body and Accessories C900M Blackout (B/O) and Trailer Harness to Transfer Connector Harness • Connector Part Information 12010717 • 3-Way F Weather Pack TWR (BK) Connector Part Information Wire Color Circuit No. BN 900 Blackout (B/O) Marker Lamps A B YE 18 S/T Lamp Feed (Left) C BK 150 Ground Pin A Function • 12015793 • 3-Way M Weather Pack TWR (BK) Wire Color Circuit No.
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Body and Accessories Wiring Systems 8-161 C902M Blackout (B/O) and Trailer Harness to Rear Blackout (B/O) Lamp • Connector Part Information • 12015792 2-Way F Weather Pack TWR (BK) Pin Wire Color Circuit No. A GN/WH 902 B BN/WH 900 Connector Part Information • 12010973 • 2-Way M Weather Pack TWR (BK) Pin Wire Color Circuit No.
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8-162 Wiring Systems Body and Accessories C904M CHSML Harness to CHSML Lamp Harness • Connector Part Information • 12052641 2-Way F MP 150 Series (BK) Pin Wire Color Circuit No. A BK 1620 B BU 1050 Connector Part Information • 12162000 • 2-Way M MP 150 Series (BK) Pin Wire Color Circuit No.
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Body and Accessories Wiring Systems 8-163 C906M Production Extension Harness to Blackout (B/O) and Trailer Harness • Connector Part Information • 1535465 7-Way F Metri Pack 280 Sealed (BK) Connector Part Information • 15317327 • 7-Way M Metri Pack 280 Sealed (BK) Pin Wire Color Circuit No.
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8-164 Wiring Systems Body and Accessories C907M Blackout (B/O) and Trailer Harness to Production Extension Harness • Connector Part Information • 1535465 7-Way F Metri Pack 280 Sealed (BK) Pin Wire Color Circuit No. A L-GN 1624 B BK 1750 C BU 47 D D-GN E Connector Part Information • 15317327 • 7-Way M Metri Pack 280 Sealed (BK) Pin Wire Color Circuit No.
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Body and Accessories Wiring Systems 8-165 Repair Instructions Auxiliary Lamp Harness Replacement – Front Removal Procedure Caution: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the battery cables. Refer to Battery Cable Disconnect/Connect Procedure in Engine Electrical. 2. Remove the radiator grille brush guard. Refer to Center Radiator Grille Brush Guard Replacement and Outer Radiator Grille Brush Guard Replacement or Radiator Grille Brush Guard Replacement in Bumpers. 3.
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8-166 Wiring Systems Body and Accessories Installation Procedure 1. Connect the forward connector of the auxiliary harness to the auxiliary I/P harness connector and attach the tiewraps. 2. Install the forward auxiliary harness (2) to the vehicle. 3. Install the auxiliary harness under the battery tray area and install the wiring harness straps. 4. Install the auxiliary harness under the washer fluid reservoir area and install the wiring harness straps along the fender interior. 5.
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Body and Accessories Installation Procedure Wiring Systems 8-167 1. Install the rear lamp harness on the rear bumper. 2. Connect the rear lamp harness connector (5) to the extension harness. 3. Connect the relay connectors to the relays on the rear relay block (3). 4. Connect the commercial and the military trailer connectors (6, 7) to the harness. 5. Connect the license plate lamp from the harness connector (2). 6.
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8-168 Wiring Systems Body and Accessories Installation Procedure 1. Install the connector to the rear lamp harness. 2. Install the auxiliary rear lamp harness extension along the path of the existing harness and vehicle frame. 3. Remove supports and lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in the 2006 C/K Truck Service Manual. 4. Install the connector (1) to the I/P auxiliary harness and wiring harness straps (2) holding to the lamp harness. 5.
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Body and Accessories Installation Procedure Wiring Systems 8-169 1. Rivet the bracket (1) to the electrical center cover. 2. Set the electrical center block in its resting position until the tabs (3) lock into place. 3. Install the electrical center cover assembly (1). 4. Install the top cover (2). 5. Install the fender upper brace. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Install the upper brace fasteners. Tighten Tighten the fasteners to 25 N•m (18 lb ft). 7.
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Index 1 A Air Filter Repair Air Filter Restriction Gage Adapter Replacement ................................................ 8-65 Air Filter Restriction Gage Hose Replacement ................................................ 8-62 Air Filter Restriction Gage Replacement ......... 8-61 Axle Description Front Axle Vent Tube Filter Description............. 4-4 Rear Axle Vent Tube Filter Description ............. 4-6 Repair Front Axle Vent Tube Filter Replacement .........
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2 Index CTSY Lamps Diagnosis CTSY Lamps Operate in Blackout (B/O) Mode ..........................................................8-105 D Data Plate Government Vehicle Data Plate Replacement....................................................8-69 Shipping Data Plate Replacement ...................... 8-69 Diagnostic Starting Point – Engine Electrical.......... 6-16 Disc Brakes Repair Rear Brake Caliper Bolt Replacement............... 5-5 Rear Brake Caliper Cover Replacement ...........
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Index 3 Fastener Tightening Specifications ................. 8-29 F Fastener Notice.........................................................P-4 Fiberglass Repair Fiberglass Top Replacement............................. 8-9 Floor Mat Floor Mat Replacement ....................................... 8-70 Floor Mount Floor Mount Gun Rack Replacement.................. 8-71 Fluid and Lubricant Recommendations .................... 0-7 Frame and Underbody Repair Center Support Beam Replacement................
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4 Index Symptoms – Instrument Panel, Gages and Console ........................................................ 8-57 Repair Accessory Instrument Panel (I/P) Replacement ................................................ 8-59 Air Filter Restriction Gage Adapter Replacement ................................................ 8-65 Air Filter Restriction Gage Hose Replacement ................................................ 8-62 Air Filter Restriction Gage Replacement ......... 8-61 Voltmeter Gage Replacement ....
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Index 5 Topper Dome Lamp Replacement ................ 8-117 Topper Dome Lamp Switch Replacement – Front ...........................................................8-109 Topper Dome Lamp Switch Replacement – Rear............................................................ 8-109 Voltmeter Gage Lamp Replacement ............. 8-117 Schematics .......................................................... 8-79 Specifications Fastener Tightening Specifications .................
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6 Seats Specifications Fastener Tightening Specifications ............... 8-125 Shock Absorber Repair Shock Absorber Cover Replacement – Left ............................................................... 3-12 Shock Absorber Cover Replacement – Right ............................................................. 3-14 Skid Plate Repair Fuel Tank Skid Plate Replacement ................. 8-43 Skid Plate Repair Front Skid Plate Replacement......................... 8-39 Rear Skid Plate Replacement ..............
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Index 7 Components Tires and Wheels Component Views .............. 3-18 Description General Description ......................................... 3-33 Tires Description.............................................. 3-33 Repair Spare Tire Carrier Latch Adjustment (Swing Away) ........................................................... 3-31 Spare Tire Carrier Latch Replacement (Swing Away) ............................................... 3-29 Spare Tire Carrier Pivot Bracket Replacement (Swing Away).........