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Chevrolet Volt Service Manual

English Service Manual, to vehicles Chevrolet Volt & Opel Ampera.

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CHEVROLET VOLT & OPEL AMPERA - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual, to vehicles Chevrolet Volt & Opel Ampera.

 

CONTENTS:


1. Preface

Preface Introduction


DangerTitle Page
Dangers, Warnings, and Cautions
Introduction

Definition of Danger, Warning, Caution, and NoteABS Component Handling WarningActions to Take When Working with Fuel WarningApproved Equipment for Collision Repair WarningAssistant Driving WarningBattery Disconnect WarningBrake Dust WarningBrake Fluid Irritant WarningChecking Hot Transmission Fluid through Drain Plug Hole WarningCleaning Solvent WarningCollision Sectioning WarningCracked Window WarningDefroster Outlet WarningExhaust Service WarningExpress Window Down WarningEye Protection WarningFoam Sound Deadeners WarningFuel and Evaporative Emission Pipe WarningFuel gauge Leak WarningFuel Pipe Fitting WarningFuel Storage WarningFuel Vapour in Evaporative Emission Components WarningPetrol/Petrol Vapours WarningGlass and Sheet Metal Handling WarningHalogen Bulb WarningBonnet Hold-Open Device WarningHot Exhaust System WarningMoving Parts and Hot Surfaces WarningProtective Goggles and Glove WarningRelieving Fuel Pressure WarningRoad Test WarningSafety Glasses and Compressed Air WarningSafety Glasses WarningSafety Goggles and Fuel WarningSIR Deployed Inflator Modules Are Hot Warning SIR Inflatable Module Deployment Outside Vehicle WarningSIR Inflator Module Disposal WarningSIR Inflator Module Handling and Storage WarningSIR Seatbelt Pretensioner Handling WarningSIR Special Tool WarningSIR WarningSteering Angle Sensor Initialisation WarningTorque-to-Yield Fastener WarningWindow Retention WarningWork Stall Test WarningAir in the Power Steering System CautionAvoid Chipping or Scratching the Coating CautionBall Stud Removal Caution Belt Dressing CautionBrake Calliper CautionBrake Fluid Effects on Paint and Electrical Components CautionClearcoat/Ultraviolet Screeners CautionComponent Fastener Tightening CautionDrive Axle Caution Engine Coolant Thermostat Housing CautionExterior Trim Emblem Removal Caution Fastener Caution Filling the Master Cylinder CautionFuel and Evaporative Emission Hose/Pipe Connection Cleaning CautionHeated Oxygen and Oxygen Sensor CautionHeated Oxygen Sensor Resistance Learn Reset CautionInstalling Hoses without Twists or Bends CautionPaint Damage CautionPipe Spanner Positioning CautionPower Steering Hose Disconnected CautionSilicon Contamination of Heated Oxygen Sensors CautionSteering Column in Lock Position CautionSteering Gear Preload Adjustment CautionSteering Wheel in the Full Turn Position CautionSteering Wheel Straight and Column Locked CautionTest Probe Caution Three-Way Catalytic Converter Damage CautionTorque Reaction Against Timing Drive Chain CautionTorque-to-Yield Fastener CautionTransmission Fluid Vent Cap Removal CautionTransmission Overfill Caution Using Proper Power Steering Fluid CautionTappet Priming Caution




Window Edge Damage Caution
2. General Information

General Information
Specifications




Safety Regulations for Hybrid/Electric Vehicles
Introduction Arrows and SymbolsVehicle, Engine and Transmission ID and VIN Location, Derivative and UsageVehicle Certification, Tyre Placard, Anti-Theft, and Service Parts ID LabelRPO Code List Fasteners Thread Inserts Registered and Non-Registered TrademarksLifting and Jacking the VehicleDiagnostic Information and Procedures




Customer Concern Verification Sheets
Special Tools and Equipment



Special Tools Ordering Information
Air/Wind Noise

Diagnostic Information and Procedures


Air/Wind Noise

Tracing Powder or Chalk Test

Air Pressure Test

Soap Suds or Bubble Test



Maintenance and Lubrication
Specifications




Approximate Fluid Capacities

Fluid and Lubricant Recommendations

Maintenance Items


Maintenance


GM Oil Life System Resetting
Vibration Diagnosis and Correction

Specifications



Diagnostic Information and Procedures





Tyre and Wheel Runout Specifications
Vibration Analysis - Hub and/or Axle InputVibration Analysis - EngineEngine Order ClassificationVibration Analysis - Engine/Accessory IsolationVibration Analysis - Engine BalanceVibration Diagnostic Aids - Vibration Intermittent or Not DuplicatedBrake Disc/Drum Balance Inspection3. Body Hardware and Trim



Exterior Trim Specifications



Fastener Tightening Specifications

Repair Instructions

Emblem/Nameplate ReplacementBody Panel Paint Protector Replacement — VGCFront Side Door Window Frame Rear Applique ReplacementTailgate Side Applique ReplacementQuarter Panel Tail Lamp Upper Moulding ReplacementRear Side Door Window Frame Rear Applique ReplacementRadiator Grille ReplacementBonnet Rear Reveal Moulding ReplacementFront Wing Upper Rear Moulding ReplacementSill Panel Moulding ReplacementRoof Panel Joint Finish Molding ReplacementRear End Spoiler ReplacementSpecial Tools and Equipment


Special Tools
Floor Coverings and Headlinings

Specifications

Adhesives, Fluids, Lubricants, and Sealers

Repair Instructions


Eliminating Unwanted Odors in VehiclesFloor Carpet DryingFront Floor Panel Carpet ReplacementFront Side Door Opening Floor Carpet Retainer ReplacementRear Side Door Opening Floor Carpet Retainer ReplacementHeadlining Trim Panel Replacement
Instrument Panel and Console Trim Specifications



Fastener Tightening Specifications
Repair Instructions


Instrument Panel Lower Trim Panel Insulator ReplacementSteering Column Opening Lower Filler ReplacementInstrument Panel Side Trim Panel ReplacementInstrument Panel Upper Trim Panel ReplacementInstrument Panel Cluster Trim Plate Cover ReplacementInstrument Panel Cluster Trim Plate ReplacementInstrument Panel Upper Outer Trim Panel Replacement – Right SideInstrument Panel Upper Outer Trim Panel Replacement – Left SideInstrument Panel Lower Extension Trim Panel ReplacementUpper Trim Pad Retainer ReplacementLower Trim Pad Retainer Replacement — Inner



Lower Trim Pad Retainer Replacement — Outer

Instrument Panel Upper Centre Compartment Replacement

Instrument Panel Lower Compartment Replacement

Instrument Panel Compartment Door Dampener Replacement

Instrument Panel Tie Bar Replacement

Instrument Panel Wiring Harness Replacement

Front Floor Console Compartment Door Hinge Replacement

Front Floor Console Compartment Door Latch Replacement

Front Floor Console Side Cover Replacement

Front Floor Console Extension Replacement - Right Side

Front Floor Console Extension Replacement - Left Side

Front Floor Console Retainer Replacement

Front Floor Console Replacement

Front Floor Rear Console Replacement

Front Floor Console Armrest Replacement

Front Floor Console Armrest Hinge Cover Replacement

Front Floor Console Trim Plate Replacement

Front Floor Console Applique Replacement

Front Floor Console Rear Cover Replacement

Roof Console Replacement

Interior Trim and Panelling
Specifications



Fastener Tightening Specifications
Repair Instructions


Front Side Door Accessory Switch Mount Plate Replacement — Driver's Side DoorFront Side Door Accessory Switch Mount Plate Replacement — Passenger Side DoorRear Side Door Accessory Switch Mount Plate ReplacementFront Side Door Trim ReplacementRear Side Door Window Garnish Moulding ReplacementFront Side Door Window Garnish Moulding ReplacementRoof Rail Rear Assist Handle ReplacementInside Rearview Mirror Mount Plate Cover ReplacementSunshade ReplacementSunshade Support ReplacementWindscreen Side Garnish Moulding ReplacementCentre Pillar Trim Panel ReplacementBody Lock Pillar Upper Trim Panel ReplacementQuarter Inner Trim Finish Panel ReplacementRear End Trim Finish Panel ReplacementRear Compartment Floor Stowage Compartment Cover Handle ReplacementRear Compartment Floor Stowage Trim Compartment ReplacementRear Compartment Floor Panel Trim ReplacementRear Side Door Trim Replacement



Liftgate Window Side Garnish Moulding ReplacementLiftgate Window Upper Garnish Moulding ReplacementTailgate Upper Trim Finish Panel ReplacementTailgate Lower Trim Finish Panel ReplacementBody Side Air Outlet Deflector Replacement 4. Body Repair
Bolted Exterior Body Panels and Closures

Specifications



Fastener Tightening Specifications

Diagnostic Information and Procedures

DTC B3006 DTC P257D-P257F Symptoms - Bolted Exterior Body Panels and ClosuresBonnet Ajar Indicator/Message MalfunctionRepair Instructions


Front Suspension Strut Housing Brace ReplacementBonnet Primary Catch Release Cable ReplacementFront Side Door AdjustmentFront Side Door ReplacementRear Side Door AdjustmentRear Side Door ReplacementFront Wing Replacement – Left SideFront Wing Replacement – Right SideLiftgate AdjustmentLiftgate ReplacementFront Side Door Upper Hinge and Lower Hinge ReplacementBonnet Hinge Replacement — VoltTailgate Hinge ReplacementRear Side Door Upper Hinge and Lower Hinge ReplacementBonnet AdjustmentBonnet Replacement — VoltBonnet Insulator Replacement — VoltBonnet Primary and Secondary Latch Replacement — VoltFront Side Door Check Link ReplacementRear Side Door Check Link ReplacementFuel Tank Filler Door ReplacementFuel Tank Filler Pipe Housing ReplacementBonnet Hold-Open Rod ReplacementBonnet Front Weatherstrip Replacement — VoltBonnet Rear Weatherstrip Replacement — VoltFront Compartment Front Sight Shield Replacement — VoltFront Compartment Side Sight Shield Replacement — VoltLiftgate Strut Replacement





Front or Rear Side Door Lower Weatherstrip ReplacementFront Side Door Weatherstrip Replacement - Door SideFront Side Door Weatherstrip Replacement - Body SideLiftgate Weatherstrip ReplacementRear Side Door Weatherstrip Replacement - Door SideRear Side Door Weatherstrip Replacement - Body SideDescription and Operation


Bonnet Ajar Indicator Description and Operation
Bumpers and Fascias

Specifications



Fastener Tightening Specifications
Repair Instructions


Front Bumper Energy Absorber Replacement — VoltFront Bumper Fascia Removal and Installation — VoltFront Bumper Fascia Guide ReplacementFront Bumper Fascia Centre Support ReplacementFront Bumper Fascia Centre Support Bracket ReplacementFront Bumper Lower Fascia Replacement — VoltFront Bumper Upper Fascia Replacement — VoltFront End Panel Outer Deflector Replacement — VoltFront End Panel Centre Deflector Replacement — VoltRear Bumper Fascia Removal and Installation — VoltRear Bumper Fascia Guide ReplacementRear Bumper Fascia Inner Guide ReplacementRear Bumper Fascia Outer Guide ReplacementRear Bumper Upper Fascia Replacement — VoltRear Bumper Lower Fascia Replacement — VoltRear Bumper Energy Absorber Replacement — VoltRear Bumper Impact Bar ReplacementCollision Repair
Specifications



Dimensions - BodyVisual Identification

Structure Identification

Repair Instructions


Front Bumper Impact Bar ReplacementHeadlamp Mount Panel ReplacementFront End Upper Tie Bar Support ReplacementFront Wheelhouse Front Panel ReplacementFront Wheel housing Panel ReplacementFront Compartment Upper Side Rail ReplacementFront Hinge Pillar Body SectioningBody Hinge Pillar Lower Reinforcement Replacement



Roof Outer Panel ReplacementRocker Inner Panel ReplacementRocker Outer Panel SectioningBody Side Outer Panel Reinforcement ReplacementBody Side Inner Panel SectioningRear Compartment Floor Panel SectioningRear Wheelhouse Panel ReplacementQuarter Outer Panel SectioningBody Rear End Panel ReplacementFront Wing Front Bracket ReplacementFront Rail ReplacementCentre Pillar Inner Panel ReplacementCentre Pillar Reinforcement ReplacementCentre Pillar Sectioning – Outer Front Side Door Outer Panel ReplacementRear Side Door Outer Panel ReplacementRail Replacement – Rear SectionRear End Lower Panel Reinforcement ReplacementRear End Panel ReplacementResistance Spot-Welded Full Panel ReplacementMIG-Welded Full Panel ReplacementDescription and Operation


Dual Phase Steel High Strength Low Alloy SteelMetal Panel BondingMild Steel Ultra High Strength Dual Phase SteelUltra High-Strength SteelFrame and Underbody


Specifications



Repair Instructions





Fastener Tightening Specifications
Underbody Front Air Deflector Replacement – Left Side
Underbody Front Air Deflector Replacement – Right Side
Underbody Rear Air Deflector Replacement
Drive train and Front Suspension Frame Replacement
Drivetrain and Front Suspension Frame Front Insulator Replacement
Front Wheelhouse Front Liner Replacement
Front Wheelhouse Rear Liner Replacement

Rear Wheel housing Panel Liner Replacement
Special Tools and Equipment


Special Tools 5. Body Systems

Fixed and Movable Windows Specifications



Fastener Tightening Specifications
Schematic and Routing Diagrams


Moveable Window Schematics

Defogger Schematics



Diagnostic Information and Procedures

DTC B0283

DTC B316B, B317A, B318A, or B319A

DTC B3205

Symptoms - Fixed and Moveable Windows

Rear Window Defogger Malfunction

Power Windows Malfunction

Side Door Window Mechanical Diagnosis

Repair Instructions


Windscreen ReplacementFront Side Door Window AdjustmentFront Side Door Window ReplacementRear Side Door Window AdjustmentRear Side Door Window ReplacementLiftgate Upper Window ReplacementLiftgate Lower Window ReplacementFront Side Door Window Channel ReplacementRear Side Door Window Rear Channel ReplacementFront Side Door Window Switch ReplacementFront Side Door Window and Multifunction Switch ReplacementRear Side Door Window Switch ReplacementFront Side Door Window Regulator ReplacementWindow Motor Programming - Express FunctionFront Side Door Window Regulator Motor ReplacementRear Side Door Window Regulator ReplacementRear Side Door Window Regulator Motor ReplacementRear Side Door Window Belt Reveal Moulding Replacement — UpperRear Side Door Window Belt Reveal Moulding Replacement — LowerFront Side Door Window Belt Reveal Moulding Replacement — UpperFront Side Door Window Belt Reveal Moulding Replacement — LowerFront Side Door Window Outer Weatherstrip ReplacementRear Side Door Window Outer Weatherstrip ReplacementFront Side Door Window Rear Channel ReplacementDescription and Operation



Power Windows Description and OperationRear Window Defogger Description and OperationStationary Window Description




Special Tools and Equipment


Special Tools
Horns Specifications



Fastener Tightening SpecificationsSchematic and Routing Diagrams


Horn Schematics
Diagnostic Information and Procedures

DTC B2750
Symptoms - Horns
Horns Malfunction
Repair Instructions


Horn Replacement
Steering Wheel Horn Contact Replacement
Description and Operation


Horns System Description and Operation
Lighting
Specifications



Fastener Tightening Specifications
Schematic and Routing Diagrams


Headlights/Daytime Running Lights (DRL) SchematicsExterior Lamps SchematicsInterior Lights SchematicsInterior Lights Dimming SchematicsDiagnostic Information and Procedures



DTC B1395

DTC B1480

DTC B2545

DTC B257A

DTC B2580

DTC B2585 or B3867

DTC B2600 or B2605

DTC B2610

DTC B2615

DTC B2625

DTC B2645

DTC B2699

DTC B3588

DTC B3600

DTC B3650

DTC B3806

DTC B3884

DTC B3948 or B3949



DTC C0277 or C0890


DTC C0297 Symptoms - Lighting
Automatic Light Malfunction
Backup Lamps Malfunction
Courtesy Lamps Malfunction
Interior Lights Malfunction
Hazard Lamps Malfunction
Headlamps Malfunction
Interior Backlighting Malfunction
Lights On Indicator Malfunction
Park, License, and/or Tail Lamps Malfunction
Reading Lamps Malfunction
Stop Lamps Malfunction
Sunshade Illumination Malfunction
Indicator Lamps and/or Indicators MalfunctionRepair Instructions


Brake Pedal Position Sensor Calibration
Brake Pedal Position Sensor Replacement
Reading Lamp Replacement
Dome and Reading Lamp Replacement
Dome and Reading Lamp Bulb Replacement
Sun Visor Illuminated Mirror Lamp Bulb Replacement
Outside Rearview Mirror Direction Indicator Lamp Replacement
Headlamp Replacement — Volt
Headlamp Bulb Replacement
Headlamp Aiming
Front Direction Indicator Lamp Replacement — Volt
Rear Fog Lamp Replacement — Volt Ampera (T79)
Rear Fog Lamp Bulb Replacement — Volt Ampera (T79)
Rear Reflector Replacement — Volt
Front Direction Indicator Lamp Bulb Replacement — Volt
High Mount Brake lamp Replacement
Cargo Centre Courtesy Lamp Bulb Replacement
Reverse Lamp Replacement
Reverse Lamp Bulb Replacement
Rear Number plate Lamp Replacement
Rear Number Plate Light Bulb Replacement
Tail Lamp Replacement
Rear Compartment Courtesy Lamp ReplacementDescription and Operation


Exterior Lighting Systems Description and OperationInterior Lighting Systems Description and Operation





Special Tools and Equipment


Special Tools
Mirrors Specifications

Fastener Tightening SpecificationsAdhesives, Fluids, Lubricants, and Sealers

Schematic and Routing Diagrams


Inside Rearview Mirror Schematics

Outside Rearview Mirror Schematics



Diagnostic Information and Procedures

Symptoms - MirrorsHeated Mirrors Malfunction Automatic Day-Night Mirrors MalfunctionPower Mirror Folding MalfunctionPower Mirror Malfunction Repair Instructions


Outside Rearview Mirror Applique ReplacementOutside Rearview Mirror ReplacementOutside Rearview Mirror Housing Cover ReplacementOutside Rearview Mirror Housing Bezel ReplacementOutside Remote Control Rearview Mirror Switch ReplacementOutside Rearview Mirror Inner Actuator ReplacementOutside Rearview Mirror Glass ReplacementInside Rearview Mirror ReplacementInside Rearview Mirror Bracket Installation Description and Operation



Automatic Day-Night Mirror Description and OperationOutside Mirror Description and Operation
Vehicle Access Specifications



Fastener Tightening SpecificationsSchematic and Routing Diagrams


Door Lock/Indicator SchematicsRelease Systems Schematics — Release System Schematics Release Systems Schematics — Liftgate Schematics
Diagnostic Information and Procedures


DTC B2500

DTC B3125, B3130, or B3135

DTC B3140 or B3150

DTC B3265

DTC B3618

DTC B3930

DTC P0CC6



DTC P0CC7, P0CC9, or P0CCA


DTC P0CCC, P0CCE, or P0CCF DTC P0CD1
DTC P0CD2
DTC P04B6
DTC P04B8-P04BA or P04DC
DTC P04BB, P04BC, or P04C0
DTC P04C3-P04C6
DTC P04C8, P04CA, or P04CB
DTC P169D
Symptoms - Vehicle Access
Charger Door Ajar Indicator Malfunction
Charger Door Release Malfunction
Exterior Door Handle Switch Malfunction – DTC B1474, B1534, B1535, or B3849
Fuel Filler Door Ajar Indicator Malfunction
Fuel Filler Door Release Malfunction
Hatch Release Malfunction
Door Ajar Indicator Malfunction
Power Door Child Lock Malfunction
Power Door Lock Key Cylinder Switches Malfunction
Power Door Locks Malfunction
Rear Hatch/Gate Ajar Indicator MalfunctionRepair Instructions


Fuel Tank Filler Door Lock Actuator Replacement
Front Side Door Inside Handle Cable Replacement
Rear Side Door Inside Handle Cable Replacement
Front Side Door Lock Cylinder Replacement
Opening the Liftgate Without Electrical Power
Front Side Door Outside Handle Replacement — Base
Front Side Door Outside Handle Replacement — Pass Key Entry ATH
Front Side Door Outside Handle Bracket Replacement
Rear Side Door Outside Handle Bracket Replacement
Liftgate Catch Replacement
Rear Side Door Outside Handle Replacement
Front Side Door Lock Cylinder Opening Cover Replacement
Rear Side Door Lock Cylinder Opening Cover Replacement
Front Side Door Lock Replacement
Rear Side Door Lock Replacement
Front Side Door Locking Rod Replacement
Front Side Door Lock Cylinder Rod Replacement
Front Side Door Outside Handle Rod Adjustment
Front Side Door Outside Handle Rod Replacement
Rear Side Door Locking Rod Replacement




Rear Side Door Outside Handle Rod AdjustmentRear Side Door Outside Handle Rod ReplacementFront Side Door Lock Striker AdjustmentFront Side Door Lock Striker ReplacementLiftgate Catch Striker ReplacementRear Side Door Lock Striker AdjustmentRear Side Door Lock Striker ReplacementRear Compartment Lid and Fuel Filler Door Release Switch ReplacementOpening the Fuel Tank Filler Door when the Door Lock MalfunctionsFuel Tank Filler Door Lock Release Switch ReplacementCharger Door Release Switch ReplacementTailgate Release Switch ReplacementDescription and Operation


Charge Port Door Description and OperationDoor Ajar Indicator Description and OperationFuel Fill Door Description and OperationLiftgate Ajar Indicator Description and OperationPower Door Locks Description and OperationRear Hatch/Gate Description and OperationWipers and Washers
Specifications



Fastener Tightening Specifications
Schematic and Routing Diagrams


Wiper/Washer Schematics
Diagnostic Information and Procedures


DTC B371A

DTC B3873

Symptoms - Wiper/Washer Systems

Windscreen Wiper System Malfunction

Washer Malfunction

Wiper Blade Element Check

Repair Instructions



Windscreen Wiper and Washer Switch ReplacementWindscreen Washer Nozzle ReplacementWindscreen Washer Pump Hose ReplacementWindscreen Washer Solvent Container Filler Tube ReplacementWindscreen Washer Solvent Container Grommet ReplacementWindscreen Washer Solvent Container ReplacementWindscreen Washer Pump ReplacementWindscreen Washer Solvent Level Sensor ReplacementPlenum Upper Panel Insulator ReplacementPlenum Drain Tube ReplacementAir Inlet Grille Panel Replacement




Air Inlet Grille Panel Extension Replacement

Windscreen Wiper Arm Replacement — Driver

Windscreen Wiper Arm Replacement — Passenger

Windscreen Wiper Blade Replacement — Driver

Windscreen Wiper Blade Replacement — Passenger

Windscreen Wiper Motor Replacement

Windshield Wiper Transmission Replacement

Windshield Glass Cleaning

Wiper Blade Element Cleaning

Wiper Chatter Repair

Description and Operation


Wiper/Washer System Description and Operation 6. Brakes

Antilock Brake System

Specifications



Fastener Tightening SpecificationsSchematic and Routing Diagrams


Antilock Brake System Schematics
Diagnostic Information and Procedures


DTC C0035-C0050, C1207-C1210, C1221-C1228, or C1232-C1235
DTC C005A
DTC C0110, C12E0, C12E8, or C12E9
DTC C012A, C128B, C128E, or C12B2-C12B4
DTC C012B or C12B6-C12B8
DTC C012C, C121A, C128C, C128F, C12B9, C12BA, C12BB, or C12F7
DTC C012D, C120A, C128A, C128D, C12BC, or C12BE
DTC C012E or C12FE
DTC C012F, C12A7, C12DC, or C12DD
DTC C0161
DTC C0186, C0196, or C0287
DTC C0201, C120D, or C120E
DTC C0242 or P0856
DTC C0245, C122E
DTC C0252
DTC C0256, C12E6, or C12E7
DTC C0294, C120C, or C12F8
DTC C0299 or C12FF
DTC C029C, C120C, C129A-C129F, C12B1, or C12F8
DTC C0552
DTC C0561
DTC C056D, C121C-C121F, C123A-C1256, C126E-C127D, C12C2-C12DF, or C12F2-C12F6
DTC C0574
DTC C0710 DTC C0870 or C12E4




DTC C0880, C12E5, or C120F

DTC C0898

DTC C0914

DTC C1120 or C1121

DTC C1122 or C1123

Symptoms - Antilock Brake System

ABS Indicator Malfunction

Traction Control/Stability Control Indicator Malfunction

Repair Instructions


Antilock Brake System Automated Bleed
Steering Angle Sensor Centring
Electronic Brake Control Module Replacement
Electronic Brake Control Module with Brake Pressure Modulator Valve Replacement
Brake Control Brake Pedal Position Sensor Replacement
Electronic Brake Control Position Sensor Replacement
Brake Pressure Modulator Valve Pressure Sensor Calibration
Brake Pressure Modulator Valve Bracket Replacement
Front Wheel Speed Sensor Replacement
Rear Wheel Speed Sensor Replacement
Vehicle Yaw Sensor Learn

Vehicle Yaw Sensor with Vehicle Lateral and Longitudinal Accelerometer Replacement
Description and Operation


ABS Description and Operation
Special Tools and Equipment


Special Tools Disc Brakes


Specifications

Fastener Tightening Specifications
Disc Brake Component Specifications
Adhesives, Fluids, Lubricants, and Sealers
Diagnostic Information and Procedures

Brake Disc Thickness Measurement
Brake Disc Thickness Variation Measurement
Brake Disc Surface and Wear Inspection
Brake Disc Assembled Lateral Runout Measurement
Brake Pad Inspection
Brake Calliper Inspection
Front Disc Brake Mounting and Hardware Inspection

Rear Disc Brake Mounting and Hardware Inspection
Repair Instructions


Front Disc Brake Pads Replacement

Rear Disc Brake Pads Replacement





Front Brake Calliper Replacement
Rear Brake Calliper Replacement
Front Brake Calliper Overhaul
Rear Brake Calliper Overhaul
Front Brake Calliper Hardware Replacement
Rear Brake Calliper Hardware Replacement
Front Brake Calliper Bracket Replacement
Rear Brake Calliper Bracket Replacement
Front Brake Disc Replacement
Rear Brake Rotor Replacement
Front Brake Shield Replacement
Rear Brake Shield Replacement
Brake Disc Assembled Lateral Runout Correction
Brake Rotor Assembled Lateral Runout Correction - Indexing
Brake Rotor Assembled Lateral Runout Correction - Correction Plates
Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe

Brake Disc Refinishing
Description and Operation


Disc Brake System Description and Operation
Special Tools and Equipment


Special Tools
Hydraulic Brakes

Specifications


Fastener Tightening Specifications
Brake Component Specifications
Brake System Specifications
Adhesives, Fluids, Lubricants, and Sealers

Schematic and Routing Diagrams


Hydraulic Brake Schematics
Diagnostic Information and Procedures


DTC C0267
Symptoms - Hydraulic Brakes
Brake Warning Indicator Malfunction
Brake Pulsation
Brake System Noise
Braking Action Uneven - Pulls to One Side
Braking Action Uneven - Front to Rear
Brake Pedal Excessive Travel
Brake Pedal Excessive Effort
Brakes Drag
Brake System Slow Release
Brake Fluid Loss
Disc Brake System Diagnosis




Brake Hydraulic and Assist System DiagnosisBrake System Vehicle Road TestBrake Pedal Travel Measurement and InspectionBrake System External Leak InspectionBrake System Internal Leak TestHydraulic Brake Component Operation Visual InspectionBrake Pipe and Hose InspectionRepair Instructions

Master Cylinder Reservoir Filling
Master Cylinder Reservoir Replacement
Master Cylinder Replacement
Master Cylinder Bench Bleeding
Brake Fluid Level Indicator Switch Replacement
Brake Pedal Assembly Replacement
Brake Pipe Replacement
Brake Master Cylinder Reservoir Hose Replacement
Front Brake Hose Replacement
Rear Brake Hose Replacement
Hydraulic Brake System Bleeding — Pressure

Hydraulic Brake System Flushing
Description and Operation

Brake System, Hydraulic, Assist, and Control Description and Operation
Brake Warning System Description and Operation
Hydraulic Brake System Description and Operation
Special Tools and Equipment


Special Tools Park Brake

Specifications

Fastener Tightening Specifications
Schematic and Routing Diagrams


Park Brake System Schematics
Diagnostic Information and Procedures


DTC C028A
DTC C028B
DTC C028D
DTC C028F
DTC C0293
DTC C0298
DTC C0558
DTC C0561
DTC C0574
Symptoms - Park Brake
Park Brake Will Not Hold or Release




Park Brake System Diagnosis

Repair Instructions

Electronic Parking Brake Control Module Replacement

Parking Brake Switch Replacement

Handbrake Cable Replacement

Handbrake Rear Cable Replacement - Left Side

Handbrake Rear Cable Replacement - Right Side

Handbrake Cable Adjuster Disabling

Handbrake Cable Adjuster Enabling

Description and Operation

Electronic Handbrake Control Module Description

Park Brake System Description and Operation

7. Diagnostic Overview, Starting Point, and Programming

Programming and Setup

Repair Instructions


Accessory DC Power Control Module Programming and SetupAir Conditioning Compressor Control Module Programming and SetupAudio Amplifier Programming and SetupBattery Charger Programming and SetupBattery Energy Control Module Programming and SetupBody Control Module Programming and SetupControl Solenoid Valve and Transmission Control Module Assembly Programming and Setup — 4ET50Coolant Heater Control Module Programming and SetupDrive Motor Generator Power Inverter Module Programming and SetupElectronic Brake Control Module Programming and SetupElectronic Handbrake Control Module Programming and SetupEngine Control Module Programming and SetupFuel Pump Flow Control Module Programming and SetupHeated Seat Control Module Programming and SetupHybrid Battery Interface Control Module Programming and SetupHybrid Powertrain Control Module 2 Programming and SetupHVAC System Control Module Programming and SetupInflatable Restraint Sensing and Diagnostic Module Programming and SetupInstrument Cluster Programming and SetupKeyless Entry Control Module Programming and SetupMobile Telephone Control Module Programming and SetupObject Alarm Module Programming and SetupPassenger Presence System Programming and SetupPower Steering Control Module Programming and SetupRadio Control Programming and SetupRadio Programming and SetupRemote Control Door Lock Receiver Programming and SetupSteering Column Lock Control Module Programming and Setup



Theft Deterrent Module Programming and SetupTyre Pressure Indicator Receiver Programming and SetupSpecial Tools and Equipment



Special Tools
Vehicle Diagnostic Information


Specifications

Body Control Module Scan Tool InformationDriver Seat and Passenger Seat Heater Control Module Scan Tool InformationElectronic Brake Control Module Scan Tool Information Electronic Parking Brake Control Module Scan Tool InformationEngine Control Module Scan Tool InformationFuel Pump Flow Control Module Scan Tool InformationHybrid Powertrain Control Module 2 Scan Tool InformationInflatable Restraint Passenger Presence System Scan Tool InformationInflatable Restraint Sensing and Diagnostic Module Scan Tool InformationInstrument Cluster Scan Tool Information Keyless Entry Control Module Scan Tool InformationMobile Telephone Control Module Scan Tool InformationObject Alarm Module Scan Tool InformationPower Steering Control Module Scan Tool InformationRadio Scan Tool Information Steering Column Lock Control Module Scan Tool InformationTransmission Control Module Scan Tool Information Diagnostic Information and Procedures


Strategy Based DiagnosisDiagnostic Procedure InstructionsDiagnostic System Check InstructionsDiagnostic Starting Point - VehicleDiagnostic System Check - VehiclePowertrain Diagnostic Trouble Code (DTC) Type DefinitionsEngine Cranks But Does Not RunInspection/Maintenance System CheckDiagnostic Repair Verification8. Driveline/Axle
Wheel Drive Shafts
Specifications




Fastener Tightening Specifications

Adhesives, Fluids, Lubricants, and Sealers


Diagnostic Information and Procedures


Symptoms - Wheel Drive Shafts
Click Noise In Turns
Clunk When Accelerating from Freewheel
Clunk Noise When Accelerating During Turns




Repair Instructions


Front Wheel Drive Intermediate Shaft Replacement
Front Wheel Drive Shaft Replacement
Front Wheel Drive Shaft Inner Joint Boot Replacement

Front Wheel Drive Shaft Outer Joint Boot Replacement
Description and Operation


Wheel Drive Shafts Description and Operation
Special Tools and Equipment


Special Tools
9. Driver Information and Entertainment

Mobile, Entertainment, and Navigation

Specifications



Fastener Tightening Specifications
Schematic and Routing Diagrams


Radio/Navigation System Schematics
Cellular Telephone Schematics
Diagnostic Information and Procedures


DTC B0000
DTC B1020
DTC B1025, B1035, B1045, or B1055
DTC B125A
DTC B1265
DTC B1271
DTC B1278 or B1279
DTC B1287
DTC B2462
DTC B2470
DTC B2485
Symptoms - Cellular Communication
Symptoms - Entertainment
Auxiliary Audio Input Malfunction
Mobile Telephone Conversation Partner Does Not Hear You
Mobile Telephone Conversation Partner Cannot Be Heard
Mobile Telephone Charging Malfunction
Mobile Telephone Microphone Malfunction
No Global Positioning System (GPS) Reception
Wireless Communication Interface Aerial Malfunction — UHP
Radio Controls Malfunction
Radio Information Display Malfunction – DTC U0257
Radio Poor Reception
Speaker Replacement Reference
Speaker Malfunction
Repair Instructions Mobile Telephone Microphone Replacement


Communication Centre Call Switch Replacement
Communication Interface Module Replacement
Wireless Communication Interface Antenna Replacement
Communication Interface Module Bracket Replacement
Radio Replacement
Radio Control Assembly Replacement
Audio Disc Player, USB, Auxiliary In, and Memory Card Receptacle Replacement
Radio Speaker Amplifier Replacement
Navigation Signal Splitter Replacement
Radio Antenna Base Replacement
Radio Aerial Replacement
Radio and Telephone Control Switch Replacement

Radio Windscreen Side Garnish Moulding Speaker Replacement
Radio Front Side Door Speaker Replacement
Radio Rear Side Door Speaker Replacement

Radio Rear Compartment Speaker Replacement
Description and Operation


Cellular Telephone Description and Operation
Radio/Audio System Description and Operation
Special Tools and Equipment


Special Tools
Displays and Gauges

Specifications



Ambient Air Temperature Sensor Resistance
Schematic and Routing Diagrams

Instrument Cluster Schematics
Driver Information System Schematics
Audible Warnings Schematics
Diagnostic Information and Procedures

DTC B0550
Symptoms - Displays and Gauges
Chime Malfunction
Driver Information Centre Switch Malfunction - DTC B3567
Engine Oil Pressure Indicator Malfunction – DTC P0520
Fuel Gauge Malfunction - DTC P0461-P0464
Instrument Cluster Gauges Malfunction
Instrument Cluster Display Malfunction

Speedometer and/or Odometer Malfunction
Repair Instructions


Driver Information Display ReplacementDriver Information Display and Multifunction Switch ReplacementInstrument Cluster Replacement




Battery Charge Indicator ReplacementAccessory Switch ReplacementDescription and Operation

Audible Warnings Description and OperationDriver Information Centre (DIC) Description and OperationIndicator/Warning Message Description and OperationInstrument Cluster Description and OperationSecondary and Configurable Customer Controls


Schematic and Routing Diagrams



Steering Wheel Secondary/Configurable Control Schematics
Diagnostic Information and Procedures


Symptoms - Secondary and Configurable Customer ControlsSteering Wheel Controls Malfunction
Description and Operation


Steering Wheel Controls Description and Operation 10. Engine

Cruise Control
Schematic and Routing Diagrams




Cruise Control Schematics
Diagnostic Information and Procedures


DTC B3794 DTC P0564 DTC P0571 DTC P0703 Symptoms - Cruise ControlCruise Control Indicator Malfunction Cruise Control Malfunction Repair Instructions



Cruise Control Switch Replacement
Description and Operation



Cruise Control Description and Operation
Engine Controls/Fuel – 1.4L (LUU)

Specifications


Temperature Versus ResistanceAltitude Versus Barometric Pressure Ignition System SpecificationsFastener Tightening SpecificationsAdhesives, Fluids, Lubricants, and Sealers Schematic and Routing Diagrams



Engine Controls Schematics
Diagnostic Information and Procedures


DTC P0010 or P0013

DTC P0011 or P0014



DTC P0016 or P0017 DTC P0030, P0036, P0053, P0054, P0135, or P0141 DTC P0101 DTC P0102 or P0103 DTC P0106 DTC P0107 or P0108 DTC P0111 DTC P0112, P0113, or P0114 DTC P0116 DTC P0117, P0118, or P0119 DTC P0121-P0123, P0222, P0223, or P2135 DTC P0128 DTC P0131, P0132, P0134, P0137, P0138, or P0140 DTC P0133, P013A, P013B, P013E, P013F, P1133, P2270, P2271, or P2A00 DTC P0171 or P0172 DTC P018B-P018D DTC P0201, P0202, P0203, or P0204 DTC P0231, P0232, or P023F DTC P025A DTC P0300-P0304 DTC P0315 DTC P0324, P0326, or P06B6 DTC P0325, P0327, or P0328 DTC P0335 or P0336 DTC P0340 or P0365 DTC P0341 or P0366 DTC P0351-P0354 DTC P0420 DTC P043E, P043F, or P145F DTC P0442 or P0455 DTC P0443, P0458, or P0459 DTC P0449, P0498, or P0499 DTC P0451-P0453 DTC P0497 DTC P0601-P0604, P0606, P062B, P062F, P0630, P16F3, or P2610 — ECM DTC P0601-P0604, P0606, or P062F — Fuel Pump Control ModuleDTC P0628 or P0629 DTC P0641 or P06A6 — Fuel Pump Control ModuleDTC P0641, P0651, P0697, or P06A3 — ECM DTC P0650 DTC P0685, P0689, P0690, or P1682 DTC P069E DTC P0700 DTC P0AC4


DTC P1101
DTC P121B or P121C
DTC P1255 or P064A
DTC P1400
DTC P1458-P145A
DTC P145C or P145D
DTC P145E
DTC P1461
DTC P1516, P2101, P2119, or P2176
DTC P15F9
DTC P15FB
DTC P162D
DTC P1B12
DTC P1E00
DTC P2122, P2123, P2127, P2128, or P2138
DTC P219A
DTC P2400-P2402
DTC P2418-P2420
DTC P2422
DTC P2450
DTC P2534 — Fuel Pump Control Module
DTC P2537
DTC P2618 or P2619
DTC P2635 — Fuel Pump Control Module
Symptoms - Engine Controls
Poor Fuel Fill Quality
Malfunction Indicator Lamp (MIL) Diagnosis
Engine Cranks But Does Not Run
Fuel System Diagnosis
Fuel Pump Electrical Circuit Diagnosis
Fuel Injector Solenoid Coil Test
Fuel Injector Balance Test
Alcohol/Contaminants-in-Fuel Diagnosis
Evaporative Emission Control System Diagnosis
Electronic Ignition System Diagnosis
Inspection/Maintenance System Check
Inspection/Maintenance Complete System Set Procedure
Inspection/Maintenance (I/M) Test DTC TableRepair Instructions


Engine Control Module Replacement
Engine Control Module Bracket Replacement
Crankshaft Position System Variation Learn Throttle/Idle Learn



Engine Coolant Temperature Sensor Replacement - Thermostat
Engine Coolant Temperature Sensor Replacement — Water Outlet
Mass Airflow Sensor with Inlet Air Temperature Sensor Replacement
Manifold Absolute Pressure Sensor Replacement
Heated Oxygen Sensor Replacement - Sensor 1
Heated Oxygen Sensor Replacement - Sensor 2
Accelerator Pedal Position Sensor Replacement
Throttle Body Assembly Replacement
Throttle Body Inspection and Cleaning
Fuel Pressure Gauge Installation and Removal
Fuel Tank Draining
Fuel Tank Replacement
Fuel Pressure Sensor Replacement - Fuel Feed Pipe
Fuel Tank Filler Pipe Replacement
Fuel Feed Pipe Replacement — Chassis
Fuel Feed Pipe Replacement — Engine Compartment
Fuel Tank Fuel Pump Module Replacement
Fuel Pump Flow Control Module Replacement
Fuel Tank Pressure Sensor Replacement
Fuel Level Sensor Replacement
Plastic Collar Quick Connect Fitting Service
Fuel Injection Fuel Rail Assembly Replacement
Fuel Injector Replacement
Evaporative Emission Canister Vent Solenoid Valve Replacement
Evaporative Emission Canister Replacement
Evaporative Emission Canister Purge Solenoid Valve Replacement
Evaporative Emission System Vacuum Leak Detection Pump Replacement
Evaporative Emission System Cleaning
Ignition Coil Replacement
Spark Plug Inspection
Spark Plug Replacement
Camshaft Position Actuator Solenoid Valve Replacement — Exhaust
Camshaft Position Actuator Solenoid Valve Replacement — Intake
Crankshaft Position Sensor Replacement
Camshaft Position Sensor Replacement — Exhaust
Camshaft Position Sensor Replacement — Intake
Knock Sensor Replacement
Air Cleaner Outlet Duct Replacement
Air Cleaner Resonator Outlet Duct Replacement
Air Cleaner Element Replacement
Air Cleaner Assembly ReplacementDescription and Operation


Camshaft Actuator System DescriptionElectronic Ignition System DescriptionEngine Control Module DescriptionEngine Maintenance and Fuel Monitor DescriptionEvaporative Emission Control System DescriptionFuel System DescriptionThrottle Actuator Control (TAC) System Description

Special Tools and Equipment



Special Tools — Diagnostic Tools

Engine Cooling



Specifications

Temperature Versus Resistance
Fastener Tightening Specifications
Engine Cooling System Specifications
Adhesives, Fluids, Lubricants, and Sealers

Schematic and Routing Diagrams


Engine Cooling Schematics
Diagnostic Information and Procedures

DTC P00B3 or P00B4
DTC P00B6
DTC P00B7
DTC P0597-P0599
DTC P1485-P1487
DTC P2181
Symptoms - Engine Cooling
Engine Overheating
Loss of Coolant
Thermostat Diagnosis
Engine Fails To Reach Normal Operating Temperature
Pressure Cap Testing

Cooling System Leak Testing
Repair Instructions


Cooling System Draining and FillingFlushingRadiator CleaningCoolant Recovery Reservoir ReplacementRadiator Inlet Hose ReplacementRadiator Outlet Front Hose ReplacementRadiator Upper Bracket ReplacementCooling Fan and Shroud ReplacementEngine Coolant Thermostat ReplacementEngine Coolant Air Bleed Hose Connector ReplacementWater Outlet Replacement




Water Inlet Replacement

Water Pump Belt Replacement

Water Pump Replacement

Engine Coolant Temperature Sensor Replacement

Radiator Replacement

Radiator Air Lower Baffle and Deflector Replacement

Radiator Air Side Baffle Replacement – Left Side

Radiator Air Side Baffle Replacement – Right Side

Radiator Air Seal Replacement

Special Tools and Equipment


Special ToolsEngine Electrical

Schematic and Routing Diagrams



Starting and Charging Schematics
Diagnostic Information and Procedures


DTC B1325, B1330, B1517, C0800, C0899, C0900, C12E1, C12E2, P0562, P0563, P1A0C, P1A0D, or P1EFC DTC B1516 DTC B151A DTC B1527 Symptoms - Engine ElectricalBattery Inspection/TestBattery ChargingBattery Electrical Drain/Parasitic Load TestCharging System TestRepair Instructions



Battery Positive and Negative Cable Replacement

Battery Positive Cable Replacement

Battery Replacement


Description and Operation


Battery Description and Operation

Charging System Description and Operation

Electrical Power Management Description and Operation

Starting System Description and Operation

Special Tools and Equipment



Special ToolsEngine Exhaust

Specifications



Fastener Tightening Specifications
Diagnostic Information and Procedures


Symptoms - Engine Exhaust

Restricted Exhaust

Exhaust Leakage

Exhaust Noise






Repair Instructions

Exhaust Manifold with Catalytic Converter Replacement
Exhaust System Replacement
Catalytic Converter Replacement
Catalytic Converter Brace Replacement
Exhaust Resonator Replacement
Exhaust Pipe Heat Shield Replacement — Front
Exhaust Pipe Heat Shield Replacement — Centre
Exhaust Pipe Heat Shield Replacement — Rear

Exhaust Rear Silencer Replacement
Description and Operation


Exhaust System Description
Special Tools and Equipment


Special Tools
Engine Mechanical – 1.4L (LUU)

Specifications

Fastener Tightening Specifications
Engine Mechanical Specifications
Adhesives, Fluids, Lubricants, and Sealers

Visual Identification

Disassembled Views
Engine Identification
Diagnostic Information and Procedures

Symptoms - Engine Mechanical
Oil Consumption Diagnosis

Engine Noise Under Load
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Base Engine Misfire without Internal Engine Noises
Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Will Not Crank - Crankshaft Will Not Rotate
Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Rumbling and Vibration Diagnosis

Drive Belt Falls Off and Excessive Wear Diagnosis
Repair Instructions


Engine Mount Replacement - Right SideEngine Mount InspectionEngine Mount Bracket Replacement - Right SideInlet Manifold Replacement Camshaft Timing Chain ReplacementTiming Chain Tensioner ReplacementHydraulic Valve Lash Adjuster Arm ReplacementHydraulic Valve clearance Adjuster ReplacementCamshaft Intake and Exhaust Sprocket ReplacementCylinder Head ReplacementOil Pan ReplacementAutomatic Transmission Flex Plate ReplacementCrankshaft Balancer ReplacementCrankshaft Front Oil Seal ReplacementCrankshaft Rear Oil Seal ReplacementEngine Front Cover with Oil Pump ReplacementEngine Oil Pressure Indicator Switch ReplacementEngine ReplacementEngine Oil and Oil Filter ReplacementCamshaft Cover ReplacementIntake Camshaft ReplacementExhaust Camshaft ReplacementValve Stem Oil Seal and Valve Spring ReplacementEngine Mount Bracket RemovalCamshaft Timing Chain InspectionCamshaft Timing Chain AdjustmentDraining Fluids and Oil Filter RemovalEngine Lift Bracket RemovalExhaust Manifold Removal Engine Coolant Thermostat Housing RemovalWater Outlet Removal Air Conditioning Compressor Bracket RemovalWater Pump Pulley RemovalCrankshaft Balancer Removal Water Pump RemovalThrottle Body RemovalInlet Manifold Removal Ignition Coil RemovalCamshaft Cover Removal Camshaft Position Actuator Solenoid Valve Removal Sump RemovalEngine Front Cover and Oil Pump RemovalCamshaft Timing Chain RemovalTiming Chain Tensioner RemovalEngine Front Cover Gasket RemovalCamshaft Sprocket RemovalIntake Camshaft Removal Exhaust Camshaft Removal Hydraulic Valve Lash Adjuster Arm RemovalHydraulic Valve clearance Adjuster RemovalCylinder Head RemovalPiston, Connecting Rod, and Bearing RemovalCrankshaft and Bearing RemovalCylinder Head DisassembleCylinder Head Cleaning and InspectionCylinder Head AssembleEngine Block DisassembleEngine Block AssemblePiston and Connecting Rod DisassemblePiston, Connecting Rod, and Bearing Cleaning and InspectionPiston and Connecting Rod AssembleIntake Manifold Disassemble Inlet Manifold Cleaning and InspectionIntake Manifold Assemble Crankshaft and Bearing Cleaning and InspectionEngine Front Cover and Oil Pump Cleaning and InspectionEngine Front Cover and Oil Pump DisassembleSump Cleaning and InspectionCrankshaft and Bearing InstallationPiston, Connecting Rod, and Bearing InstallationCylinder Head InstallationHydraulic Valve clearance Adjuster InstallationHydraulic Valve Lash Adjuster Arm InstallationIntake Camshaft Installation Exhaust Camshaft Installation Camshaft Sprocket InstallationTiming Chain Tensioner InstallationEngine Front Cover Gasket InstallationCamshaft Timing Chain InstallationEngine Front Cover and Oil Pump InstallationSump InstallationCamshaft Position Actuator Solenoid Valve Installation Camshaft Cover Installation Ignition Coil InstallationOil Filter Installation Inlet Manifold Installation Throttle Body InstallationWater Pump InstallationCrankshaft Balancer Installation Water Pump Pulley Installation






Air Conditioning Compresso