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2005 LSSV Service Manual Supplement

1. 8 5 Fastener Tightening Specifications 8 5 Repair Instructions 8 6 Upper Front Fender Reinforcement Replacement eee e ee ee e e ee 8 6 Lower Front Fender Reinforcement Replacement sesime e ee eee e e 8 7 BodyRearEnd 8 8 Specifications 8 8 Fastener Tightening Specifications 8 8 Repair Instructions 8 9 Fiberglass Top Replacement 8 9 Cargo Cover Side Rail and Hinge Replacement see eee ee v ee eee 8 10 Cargo Cover Front End Rail Replacement 8 12 Cargo Cover Rear End Rail Replacement 8 12 Cargo Cover Strut Replacement 8 13 Cargo Cover Top Bows Replacement 8 14 Cargo Cover Replacement 8 15 Cargo Cover Stowage Replacement 8 15 Body Replacement Ambulance Body 8 16 Body Replacement Maintenance Body 8 23 Description and Operation 8 26 Body Rear End Description 8 26 Special Tools and Equipment 8 26 BUIDDBEIS M ME A EY i 8 27 Specifications eee c 8 27 Fastener Tightening Specifications 8 27 Repair Instructio
2. Government Vehicle Data Plate Replacement EMME O ME Shipping Data Plate Replacement Floor Mat Replacement Floor Mount Gun Rack Replacement Lower Cab Mount Gun Rack Replacment EE RR Upper Cab Mount Gun Rack e lt lt A E Pioneer Tool Kit Bracket Replacement Enhanced Mobility Package Jack Mounting Bracket Replacement In Vehicle Tire Carrier Enhanced Mobility Package Jack Mounting Bracket Replacement Regular Cab c c I 8 86 Enhanced Mobility Package Jack Mounting Bracket Replacement Extended Cab 8 87 Enhanced Mobility Package Jack Mounting Bracket Replacement Crew Cab e name sa in a 8 87 Enhanced Mobility Package Jack Tools Mounting Bracket Replacement MM 8 88 LightingSystems 8 89 Specifications ses seen s rede dai ee 8 89 Fastener Tightening Specifications 8 89 Schematic and Routing Diagrams 8 89 Exterior Lights Schematics 8 90 Interior Lights Schematics 8 96 Interior Lights Dimming Schematics 8 97 ComponentlLocator 8 98 Lighting Systems Component Views 8 98 Lighting Systems Connector End Views 8 103 Diagnostic Info
3. 12 13 14 15 16 17 18 19 20 21 22 23 24 29 Body Connect the wiring harness for the taillamps Refer to Taillamp Replacement Maintenance Body in Lighting System Connect the wiring harness for the backup lamps 3 Refer to Backup Lamp Replacement Ambulance Body in Lighting System Connect the wiring harness for the license plate lamp 2 Refer to License Plate Lamp Replacemeni LSSV or License Plate Lamp Replacement Maintenance Body or License Plate Lamp Replacement Ambulance Body Install the wiring going to the body marker lamps and backup alarm Install the wiring harness to the ambulance in the same routing as removed Install the clamps and screws 2 Install the wiring to the distribution panels 1 in the same location as removed Install the distribution covers Tighten Tighten cover bolts 0 8 N m 7 Ib in Install the distribution cover shield Tighten Tighten shield bolts 0 8 N m 7 Ib in Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Fill the cooling system Refer to Draining and Filling Cooling System Ambulance Body in Engine Cooling Evacuate and recharge the A C system Refer to Refrigerant Recovery and Recharging in Heating Ventilation and Air Conditioning o
4. 24V Voltmeter i Gage Lamp i B Accessory i Panel 117P 1697953 89 8 josuo pue seabed jaueg 1ueuinuisu U O Q lt Body Instrument Panel Gages and Console 8 69 Component Locator Instrument Panel Gages and Console Component Views Front Side of the Instrument Panel 1694851 Legend 1 Tire Pressure Monitoring System Gage 5 Air Filter Restriction Gage 2 Tire Pressure Monitoring System 6 Fiberglass Cap Dome Lamp Switch Switch Panel 7 Blackout B O Lighting Switches 3 Power Take Off 4 24 Voltmeter Gage 2005 LSSV Service Manual Supplement 8 70 Instrument Panel Gages and Console Instrument Panel Gages and Console Connector End Views Voltmeter Gage 1694854 Connector Part e 02973781 Information 2 Way F 56 Series BK Circuit Wire Color N Voltmeter Gage B BK O Body 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 Visual Physical Inspection e Inspect for aftermarket devices which could affect the operation of the Instrument Cluster Gages Refer to Checking Aftermarket Accessories in Wiring Systems in 2005 C K Truck Service Manual Inspect the
5. 1 Drain the engine coolant Refer to Draining and Filling Cooling System Ambulance Body in Engine Cooling Caution Refer to Vehicle Lifting Caution in Cautions and Notices 2 Raise the vehicle Refer to Lifting and Jacking the Vehicle in General Information in the 2005 C K Truck Service Manual 3 Loosen the hose clamps 1 from the coolant booster pump inlet and outlet 1702779 4 Disconnect the coolant booster pump wiring 5 Remove the coolant booster pump shield retaining bolts 1 6 Remove the coolant booster pump and shield 1702777 Installation Procedure 1 Install the coolant booster pump and shield Notice Refer to Fastener Notice Fastener Notice in Cautions and Notices 2 Install the coolant booster pump retaining shield bolts 1 Tighten Tighten the bolts to 9 N m 80 Ib in 1702777 2005 LSSV Service Manual Supplement 1 6 Heating Ventilation and Air Conditioning 1702779 HVAC 3 Connect the coolant booster pump wiring 4 Reposition and tighten the hose clamps 1 to the heater water booster pump inlet and outlet 5 Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in the 2005 C K Truck Service Manual 6 Fill the engine coolant Refer to Draining and Filling Cooling System Ambulance Body in Engine Cooling Description and Operation Ambulance Heating System The purpose of the auxiliary heating system is to supply hea
6. Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices BLACKOUT 1 Disconnect the battery cables Refer to Battery DRIVE LIGH7 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 BLACKOUT 3 Remove the nuts 1 and washers holding the blackout B O switches 4 Remove the keyed washers from the accessory panel and pull the switches out 1693358 2005 LSSV Service Manual Supplement Body Installation Procedure 1 Install the switches through the accessory panel 2 Install the keyed washers on the switches Notice Refer to Fastener Notice in Cautions and Notices 3 Install the 2 washers and nuts 1 on the panel Tighten Tighten the 2 nuts to 2 8 N m 24 lb in 4 Install the accessory panel Refer to Accessory Instrument Panel I P Replacement in Instrument Panel Gages and Console 5 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure Backup Alarm 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 2 Remove the nuts 2 retaining the wiring to the alarm 3 Remove the bolts 1 retaining the alarm to the vehicle 4 Remove the alarm from the vehicle Installation Pro
7. e 12110053 e Lamp Socket Type W 2 Axial L GY Connector Part Information Circuit Wire Color No A Lamp Supply Voltage B 2005 LSSV Service Manual Supplement Lighting Systems 8 105 Trailer Lamp Connector 1465963 Connector Part e 08917884 Information 12 Way Weather Pack BK Circuit Wire Color N 1 Marker Lamps Brake Taillamp Supply Voltage Blackout B O Blackout B O Y Control Circuits 9 Blackout B O Brakelamps Blackout B O Brakelamp Brake Taillamp Supply Voltage Topper Dome Lamp Switch Connector Accessory Panel i O Zz E BN BK BN BN 1 O 18 50 02 9 15 L 9 Stoplamp Switch Output EN ETE A c IB O Zz 1704987 02965114 e 3 Way F 56 Series Unsealed BK Circuit Wire Color No witch to Switch Signal B BNWH 803 Switch to Switch Signal 12 Switch Supply Voltage Connector Part Information 8 106 Lighting Systems Topper Dome Lamp Switch Connector Cargo Box 1704987 e 02965114 e 3 Way F 56 Series Unsealed BK Circuit Wire Color No BN WH Switch to Switch Signal B BN Switch to Switch Signal C Dome Lamp Supply Voltage Voltmeter Gage Lamp Connector Part Information 743312 12004264 2F LP SOC Hardshell BK Circuit Wire Color No A B Voltmeter Gage Supply Voltage N B BK 150j Grud Connector Part Information Body Diagnostic Information and Procedures
8. 8 136 Lighting Systems Body License Plate Lamp Replacement Maintenance Body Removal Procedure 1 Ensure the headlamp switch is in the OFF position 2 Remove the license plate lamp bulb Refer to License Plate Lamp Bulb Replacement Ambulance Body or License Plate Lamp Bulb Replacement Maintenance Body 3 Pull the rubber lamp housing 1 out of the opening in the bumper 4 Disconnect the electrical connector 1692761 Installation Procedure 1 Connect the electrical connector 2 Install the lamp housing 1 into the opening in the bumper 3 Install the license plate lamp bulb Refer to License Plate Lamp Bulb Replacement Ambulance Body or License Plate Lamp Bulb Replacement Maintenance Body 1692761 License Plate Lamp Replacement Ambulance Body Removal Procedure 1 Ensure the headlamp switch is in the OFF position 2 Remove the license plate lamp bulb Refer to License Plate Lamp Bulb Replacement Ambulance Body or License Plate Lamp Bulb Replacement Maintenance Body 3 Pull the rubber lamp housing 1 out of the opening in the bumper 4 Disconnect the electrical connector 1692757 2005 LSSV Service Manual Supplement Body Installation Procedure 1 Connect the electrical connector 2 Install the lamp housing 1 into the opening in the bumper 3 Install the license plate lamp bulb Refer to License Plate Lamp Bulb Replacement Ambulance Body or License Plate
9. LSSV Service Manual Supplement Body Installation Procedure Important Use a standard 194 bulb for replacement 1 2 3 Install the bulb 1 into the voltmeter gage socket Install the lamp socket into the voltmeter Install the accessory panel Refer to Accessory Instrument Panel I P Replacement in Instrument Panel Gages and Console Topper Dome Lamp Replacement Removal Procedure l 2 3 Remove the topper dome lamp bulb Refer to Topper Dome Lamp Bulb Replacement Remove the screws 1 from the lamp Disconnect the electrical wiring and remove the lamp from the topper Installation Procedure 1 2 3 Connect the electrical wiring and install the lamp onto the topper Install the screws 1 and secure Install the topper dome lamp bulb Refer to Topper Dome Lamp Bulb Replacement 2005 LSSV Service Manual Supplement Lighting Systems 8 139 1693477 1692781 1692781 8 140 Lighting Systems Body 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 1707699 Installation Procedure 1 Install the bulb into the lamp socket 2 Install the lens into the lamp by pressing until fully seated 1707699 Backup Lamp Replacement Ambulance Body Removal Procedure 1 Remove the backup lamp bulb Refer to Backup Lamp Bulb Replacement 2 Remove
10. Maintenance Body or Rear D Ring Bracket Replacement LSSV in Frame and Underbody 3 Remove the bumper bolts 1 1698275 2005 LSSV Service Manual Supplement Body 4 Remove the bumper bracket to frame bolts 5 Remove the bracket to bumper spacer from the vehicle Installation Procedure 1 Install the bumper bracket and spacer into position Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bracket to frame bolts Tighten Tighten the side and upper bolts to 97 N m 72 Ib ft e Tighten the lower bolt to 155 N m 114 Ib ft 3 Install the bumper bolts 1 Tighten Tighten bumper bolts to 97 N m 72 Ib ft 4 Install the rear D ring 2 from the appropriate side Refer to Rear D Ring Bracket Replacement Maintenance Body or Rear D Ring Bracket Replacement LSSV in Frame and Underbody 5 Remove the supports and lower the vehicle 2005 LSSV Service Manual Supplement Bumpers 8 39 1698278 1698278 1698275 8 40 Bumpers 1702050 1702050 1700950 Body Bracket Replacement Rear Bumper Maintenance Body 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 2005 C K Truck Service Manual 2 Remove the rear hitch and reinforcement plate Refer to Trailer Hitch Reinforcement Plate Replacemen
11. Schematic and Routing Diagrams Delphi AD230 102 A TA Delphi AD244 145 A 2005 LSSV Service Manual Supplement jueuiejddng enuey 891449 ASST 5002 Starting and Charging Schematics Battery Schematic Oc 32 RD R 32 HD 32 HD Battery Battery 900 RD Frame Left 0 8 Mount 12V 32 RD 1 8004 RD E 0 8 0 m 2 i x l Winch Prep Vehicle Wiring i Load i Schematic 1 Disconnect C i Switch il Junction i Block 13 1 Underhood 900 BK i RD siz sim 32 13 AD Charging o Schematic 24V Power Distribution I i i Schematics in e he eee Wiring Systems iel ele ce o t Bus nee ee ea Starting Diesel Winch Prep Schematic in i Wiring i Schematic i Power Distribution REPRE eee Schematics in Wiring Systems 2005 C K Truck Service Manual I i i 1 Engine Electrical I G103M 32 BK Receptacle G102M 1702789 ouiDu3 1879110912 euiDu3 LL 9 jueuiejddng jenuey 891449S ASST 5002 Starting and Charging Schematics Charging Schematics 12V ke Mk ww Wr wp ww w a ww w Www ww HRS HE Www Z Z W mwy ian ne AN Engine i i Generator Control ES Field Duty Module Charge Cycle Signal C1 80 BLU ECM I indicator C2 80 CLR l 1 Control jzz OO O OOO B Winch Prep Winch Prep Wiring 4 Wiring T i Schematics I Schematics Junction Block x Underhood L BA Power Distribution B
12. 4 Install the switch to the mounting bracket and install the mounting nuts and bolts 1 Tighten Tighten the switch mounting nuts to 9 N m 80 Ib in 1703363 5 Install the switch key 1 to the switch 2 6 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure 1703362 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 Remove the positive battery cable bolt 3 cable to starter connection and spacer from the right rear underhood battery 3 Unsnap the positive battery cable cap from the frame mounted battery 4 Remove the positive battery cable bolt 5 Remove wiring harness straps and remove the positive cable 4 from the vehicle 1703364 2005 LSSV Service Manual Supplement 6 38 Engine Electrical 1703364 1703365 Engine Installation Procedure Important Ensure that all battery terminal connections are clean 1 Install the positive battery cable 4 and secure with wiring harness straps Route in the same location as removed Notice Refer to Fastener Notice in Cautions and Notices 2 Install the positive battery cable bolt to the frame mounted battery Tighten Tighten the bolt to 17 N m 13 Ib ft 3 Snap the positive battery cable cap closed 4 Inst
13. G100 the horns will sound as long as the horn switch Voltage is applied at all times to the horn relay through is depressed the 15A horn fuse in the underhood fuse block The The blackout B O service drive switch is used to blackout B O service drive switch is used to control disable the horn relay when placed in the blackout the horn relay Power is applied through OG circuit 40 B O mode When the blackout B O service to the blackout B O service drive switch which is drive switch is in the ON position power to the horn normally a closed switch When the horn switch is o depressed the horn switch contacts close providing a relay is disrupted leaving the horns inoperative 2005 LSSV Service Manual Supplement Body Instrument Panel Gages and Console 8 67 Instrument Panel Gages and Console Specifications Fastener Tightening Specifications Specification Application English Accessory Instrument Panel I P Bolts 71 Ib in Voltmeter Gage Nuts 24 lb in Schematic and Routing Diagrams 2005 LSSV Service Manual Supplement jueuiejddng jenuey 891449S ASST 5002 Instrument Cluster Schematics Voltmeter Gage 900 RD 0 8 Power Distribution Schematics in Wiring Systems Vehicle Load Disconnect Switch Rectifier Bridge A B 8008 BN 0 8 Sa e e Ga dli 24V Voltmeter Gage Fuse 5A i l 24V i Voltmeter l l l l Gage B 150 BK 0 8
14. Installation Procedure 1 Install the gage into the housing opening 2 Install the bracket 2 on the back of the voltmeter Notice Refer to Fastener Notice in Cautions and Notices 3 Install the nuts 1 on the gage studs Tighten Tighten the bolts to 0 8 N m 7 Ib in 1693469 2005 LSSV Service Manual Supplement 3 40 Tire Pressure Monitoring Suspension 4 Install the electrical connectors onto the gage 5 Install the housing 2 onto the A pillar molding and install the push pins 1 6 Remove the garnish molding Refer to Garnish Molding Replacement Windshield Pillar in Interior Trim in 2005 C K Truck Service Manual 1693468 Tire Pressure Monitoring Switch Panel Replacement 1 Remove the I P knee bolster panel Refer to Knee Bolster Replacement in Instrument Panel Gages and Console in 2005 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 5 Remove the switch panel 1 routing panel cable through the hole in the IPC bezel Note cable routing position for reinstallation 1693471 Installation Procedure 1 Apply Velcro strip to the back of the new switch panel 2 Install the switch panel 1 routing panel cable through the hole in the IPC bezel in
15. O ring Seal 2005 LSSV Service Manual Supplement 3 16 Tires and Wheels Suspension Repair nstructions Tire Mounting and Dismounting Beadlock Tools Reguired 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 1697941 4 Loosen all the nuts in a star pattern until all the nuts have been removed 1697942 2005 LSSV Service Manual Supplement Suspension 5 Apply tire soap to the edge of the outer rim flange Important Gently pry the outer flange away from the tire bead in 3 locations around the rim 6 Install a 7 16 in tire spoon 1 between the flange and the tire and pull down until the spoon is horizontal with the working surface 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 O ring and discard 10 Flip the tire assembly over and apply tire soap to the inner flange 11 Using the pry bar and tire spoon
16. Power Distribution Schematics 8 148 Ground Distribution Schematics 8 151 Harness Routing Views 8 156 Component Locator 8 160 Master Electrical Component List 8 160 Electrical Center Identification Views 8 163 Inline Harness Connector End Views 8 167 Repair Instructions 8 181 Auxiliary Lamp Harness Replacement Front 8 181 Lamp Harness Replacement Rear LSSV 8 182 Lamp Harness Replacement Rear Maintenance Body 8 183 Blackout B O Lamp Wiring Harness Front Ambulance Maintenance Body 8 184 Auxiliary Lamp Extension Harness Replacement MH Hr 8 185 Relay Mounting Bracket Replacement 8 186 12V and 24V Harness Replacement Maintenance Body 8 188 8 4 Table of Contents Body BLANK 2005 LSSV Service Manual Supplement Body Body Front End 8 5 Body Front End Specifications Fastener Tightening Specifications Specification Application English Fender Bolt 18 Ib ft Fender Reinforcement Bolt 89 Ib in 2005 LSSV Service Manual Supplement 8 6 Body Front End 1703383 1703383 Body Repair Instructions Upper Front Fender Reinforcement Replacement Removal Procedure 1 Open the
17. Raise the vehicle Refer to Lifting and Jacking the Vehicle in General Information in the 2005 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 1700615 Installation Procedure 1 Install the support beam 3 and 4 Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts 1 and nuts 2 Tighten e Tighten support beam 3 nuts and bolts to 35 N m 26 lb ft Tighten support beam 4 nuts and bolts to 50 N m 37 Ib ft 3 Install the front skid plate Refer to Front Skid Plate Replacement 4 Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in the 2005 C K Truck Service Manual 1700615 Center Support Beam Replacement Removal Procedure 1 Remove the front skid plate Refer to Front Skid Plate Replacement 2 Remove the rear skid plate Refer to Rear Skid Plate Replacement 3 Remove the rear support beams Refer to Hear Support Beam Replacement 4 Remove the front support beams Refer to Front Support Beam Replacement 5 Remove the nuts 7 and bolts 3 4 and 5 securing the brackets to the crossmembers 6 Remove the brackets 1 2 and 6 from the vehicle 1700617 2005 LSSV Service Manual Supplement Body Installation Procedure 1 Install the brackets 1 2 and 6 on the vehicle Notice Refer
18. Removal Procedure 1 Remove the P knee bolster panel Refer to Knee Bolster Replacement in Instrument Panel Gages and Console in 2005 C K Truck Service Manual Disconnect the power cable from the receiver Disconnect the display cable from the receiver Remove the screws 1 and remove the receiver 2 Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices Install the receiver 2 into the bracket and install bolts 1 Tighten Tighten the bolts to 0 8 N m 7 Ib in Connect the display cable into the receiver Connect the power cable into the receiver Install the I P knee bolster panel Refer to Knee Bolster Replacement in Instrument Panel Gages and Console in 2005 C K Truck Service Manual Program the TPMS Refer to Tire Pressure Monitoring Sensor Programming 2005 LSSV Service Manual Supplement Suspension Tire Pressure Monitoring 3 39 Tire Pressure Monitoring Gage Replacement Removal Procedure 1 Remove the garnish molding Refer to Garnish Molding Replacement Windshield Pillar in Interior Trim in 2005 C K Truck Service Manual 2 Remove the push pins 1 from the gage housing 3 Pull the housing 2 out enough to remove the gage electrical connectors 4 Remove the housing from the vehicle 1693468 5 Remove the nuts 1 from the back of the gage Remove the gage bracket 2 7 Remove the gage from the housing O 1693469
19. gently pry the inner flange from the tire bead in 3 locations 12 Using the tire spoon 1 between the flange and tire push the tire sooon down until it is horizontal to the working surface to lift the wheel flange up 2005 LSSV Service Manual Supplement Tires and Wheels 3 17 1697944 1697945 1697944 3 18 Tires and Wheels Suspension 13 Using the pry bar between the flange and tire push the tire bead down The pry bar will push the tire down and off of the 5 bead seat 14 Using the prybar 1 and tire spoon 2 work your way around the tire at intervals of 45 Important Ensure that the wheel half is placed with the O ring side facing up to avoid scratching the Surface 15 Remove the inner wheel half from the tire 1697945 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 1697946 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 1697947 2005 LSSV Service Manual Supplement Suspension Cleaning and Inspection Procedure 1 Clean the following areas Degrease the rim bead seats with denatured alcohol and dry with a clean towel Allow to dry Clean the tire beads with a clean towel to remove
20. gt ees eee es ee GENE ae OG E3 912 OG 592 1 0 L GN BK 0 8 k i Blackout Lighting S107M DRL Relay Relay Block 30 86 i i i E i 87 85 J i 1 340 i 1 0 592 L GN BK 0 8 C106M YA C C1 E3 C1 D4 Existing Wiring Disconnected From Fuse Block Underhood Refer to the 2005 C K Truck Service Manual 1693287 suejs s DunuDr1 06 8 pog jueuiejddng enuey 891449 ASST 5002 Exterior Lights Schematics Interrupt Relays UP Fuse Block F e Body CT TTT 1 Relay On Control 1 Block 9 Module YP 5 l BCM T Es A K y yaa y wi zn 2 4 Ap Caw B8 C4M B6 C2M B11 CoM F Gaa A122 2090 2226 1056 24 YE BK GY BK GY L GN 0 8 0 8 0 8 0 8 e da C307M 6 Y 7 5 1732 690 OG GY 0 8 0 8 912 RD 1 0 150 BK 0 8 S308M Back iene 30 86 30 86 30 86 Relay Backup CTSY 2 CTSY 1 Lamp Relay Relay 1450 Relay BK 1 0 87 T 87 85 87 85 AN 912 RD 0 8 C308M YB 8309M 24 173 36K S310M 12090 GY BK OG BK 690 150 OHM OG WH 0 8 0 8 GY BK BK L 5 0 8 0 8 10 S311M 1056 GY 0 8 e S S306M 2226 GY BK 0 8 COM B Wa 312M sm See a ee 24 C307M y 2 3 1 L GN 2090 2226 1056 0 8 C1 D4 A12 150 OG BK GY BK GY a 0 8 0 8 0 8 i Disconnected From Relay C3 B8 C4 B6 C2 B11 C5 F Block I P Refer to the 2005 C K Truck Service Manual Disconnected From Body Control Module BCM Refer to the 2005 C K Truck Service Manual G304M 1693288 Apog 16 3 suiejs S Buny ry jueuiejddng jenuey 891
21. 2 With the aid of an assistant place the top on the bed rails Notice Refer to Fastener Notice in Cautions and Notices 3 Install the bolts 1 and tighten Tighten Tighten bolts to 58 68 N m 43 50 Ib ft 4 Connect the electrical connection for the dome lamp 1703177 2005 LSSV Service Manual Supplement 8 10 Body Rear End Body Cargo Cover Side Rail and Hinge Replacement Removal Procedure 1 Remove the cargo cover the top bows and side struts 2 Refer to Cargo Cover Top Bows Replacement and Cargo Cover Strut Replacement 2 Remove the troop seats 1 Refer to Seat Replacement Troop in Seats 1701838 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 1703179 7 Remove the side rail 8 Remove the side rail adapter 9 Drill out the 4 existing rivnuts if damaged from the box rail 1703181 2005 LSSV Service Manual Supplement Body Installation Procedure 1 Apply 2 sided foam tape to the underside of the rails and to the edges of the mounting holes 2 Install rivnuts to the existing holes if damaged using a rivnut installer 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 ra
22. 50 N m 37 Ib ft 1701831 Important Clean any existing corrosion or paint from the body bolt flange area and ground strap end 3 Install the nut and bolt 1 for the ground strap Tighten Tighten the ground strap bolt to 25 N m 18 Ib ft 1701830 4 Install the fuel tank filler housing to fuel tank fill pipe bolts 1 Repeat step for other fuel fill Tighten Tighten the fuel filler bolts to 2 3 N m 20 Ib in 1701829 2005 LSSV Service Manual Supplement Body Body Rear End 8 21 Important Install the outlet hose in the same position and routing as removed 5 Install the outlet hose to the vehicle underbody and engine compartment 6 Install any wiring harness straps or clamps 7 Install the hose to the connection at the bulkhead 21855 8 Install the inlet hose 1 to the coolant booster pump and secure clamp 1701828 9 Install the new O ring onto the A C tubes Refer to O Ring Replacement in Heating Ventilation and Air Conditioning in the 2005 C K Service Manual 10 Install the A C hoses tube nuts 2 using a back up wrench on the fitting and tighten the fitting nut Tighten Tighten fittings 9 N m 80 Ib in 11 Install the bolt 1 and clamp securing the lines to the vehicle 1701827 2005 LSSV Service Manual Supplement 8 22 Body Rear End 1701835 NUT TAI e S NS TE mi 5 Ze Tlie CR N ha F R r r REES SUO ny CONGO 1701826 Tom tena LITT
23. CTRY Supply Voltage Inadvertent Power Inadvertent Power OG BK 1732 Supply Voltage OG BK 1732 Supply Voltage Information 2005 LSSV Service Manual Supplement 8 174 Wiring Systems Body a C306M TBC Harness to Relay Interrupt Harness 439818 611495 Connector Part 12047682 Connector Part 12047683 Information 1 Way F MP 150 Series BK Information 1 Way M MP 150 Series BK Circuit Circuit Wire Color No Wire Color No Backup Lamp Backup Lamp C307M TBC Harness to Relay Interrupt Harness T BE Lr E SHG CGL 258171 1459214 Connector Part 12065873 Connector Part 12065874 Information 7 Way F MP 100 BK Information 7 Way M MP 100 BK Circuit Circuit Wire Color No Wire Color No Dimmer Switch 5V Dimmer Switch 5V GY 1056 Reference Voltage GY 1056 Reference Voltage from Dimming Relay from Dimming Relay Dimmer Switch Signal Dimmer Switch Signal AB gg from Dimming Relay ALLE aud from Dimming Relay ot sed Dimmer Switch 5V GY 1056 Reference Voltage from BCM Dimmer Switch MESES 2090 signal from BCM Dimmer Switch uN 2226 Signal from BCM P Not uses Dimmer Switch 5V GY 1056 Reference Voltage from BCM Dimmer Switch YEK 2090 Signal from BCM Dimmer Switch GY BK 2226 Signal from BCM Dimmer Switch Low Dimmer Switch Low 3 GY BK 2226 Reference from 3 GY BK 2226 Reference from Dimming Relay Dimming Relay 2005 LSSV Service Manual Supplement Body Wiring Syst
24. Go to Horn with Blackout B O Control Go to Step 2 Circuit Operation Depress the horn switch Go to Horns Does either horn operate Inoperative One Horn E in 2005 C K Truck Service Manual Go to Step 3 1 Remove me horn interrupt reay Gis Bons 2 Connect a jumper between terminal 30 and 87 of the Inoperative in 2005 relay block C K Truck Service Does either horn operate Go to Step 4 Manual Connect a test lamp between terminal 86 of the relay block and ground Does the test lamp illuminate Go to Step 6 Go to Step 5 Connect a test lamp between terminal C of the blackout B O service switch and ground Does the test lamp illuminate Go to Step 7 Go to Step 8 Connect a test lamp between terminal 85 of the relay block and ground Does the test lamp illuminate Go to Step 9 Go to Step 10 Repair the open or high resistance in the OG circuit 912 Did you complete the repair Go to Step 13 Connect a test lamp between terminal B of the blackout B O service switch and ground Does the test lamp illuminate Go to Step 11 Go to Step 12 Repair the open or high resistance in the BK circuit 150 Did you complete the repair Go to Step 13 10 Replace the horn interrupt relay Did you complete the repair Go to Step 13 Replace the blackout B O service switch Refer to Blackout B O Switch Replacement in Lighting Systems Did you complete the replacement Go to Step 13 Repair the open or high resistance in the OG circuit 40 Did you complete
25. Install the positive slave receptacle cable in the same routing location as removed Connect the positive slave receptacle cable connector 3 to the 24V battery connection Install the negative slave receptacle cable in the same routing location as removed Connect the negative slave receptacle connector 1 to the cable ground connection Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure Slave Receptacle Harness Replacement LSSV Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure Trace the negative slave receptacle cable connector 2 to the cable ground connection Disconnect the negative slave receptacle ground cable from the ground connection Trace the positive slave receptacle cable connector 1 to the 24V battery connection Disconnect the positive slave receptacle cable 3 from the 24V battery connection 2005 LSSV Service Manual Supplement Engine 6 Disconnect the slave receptacle connectors from the slave receptacle Refer to Slave Receptacle Replacement LSSV or Slave Receptacle Replacement Ambulance Maintenance Body Remove the wiring harness straps securing the slave receptacle harness and the blackout B O harness Remove the slave receptacle harness from the bumper assembly Installation Procedure Important Verify all conn
26. Pack TWR BK TWR BK Circuit Vel Wire Color No Wire Color Right Rear Blackout B O Marker Lamps Right Rear Blackout B O Right Rear Blackout B O Right Rear Blackout B O das 258174 Connector Part didus Connector Part evi e 2 Way M Weather Pack i 2 Way F Weather Pack Inf Inf anne TWR BK A A SHD BK Circuit yin Wire Color No Wire Color Left Rear Blackout B O Left Rear Blackout B O BN WH Left Rear Blackout B O Left Rear Blackout B O Marker Lamps Marker Lamps 2005 LSSV Service Manual Supplement 8 178 Wiring Systems Body C904M CHSML Harness to CHSML Lamp Harness 635009 333041 Connector Part e 12052641 Connector Part e 12162000 Information e 2 Way F MP 150 Series BK Information e 2 Way M MP 150 Series BK Circuit Circuit Wire Color No Wire Color No e 8 R 1050 1050 283957 Connector Part lira Connector Part 12010373 e 2 Way M Weather Pack e 2 Way F Weather Pack Inf Inf nformation TWR BK nformation TWR BK Circuit Circuit Wire Color No Wire Color No Rear Marker Lamp Rear Marker Lamp Rear Stoplamp Rear Stoplamp 2005 LSSV Service Manual Supplement Body Connector Part Information A C Connector Part Information A C Wiring Systems 38 179 C906M Production Extension Harness to Blackout B O and Trailer Harness 525095 e 1535465 e 7 Way F Metri Pack 280 Sealed BK Circuit Wire Color No L GN 1624 LGN Trailer Bac
27. Please refer to the light duty series GM BODY BUILDER BOOK for further general information regarding vehicle modification Important New calibrations include maximum vehicle speed of 93 mph 150 km h The calibrations are for RPO EM7 Option Code EMP only 15130247 Repair Instructions Description and Operation Engine Control Module ECM Engine Control Module ECM Replacement Description The ECM for the enhanced mobility package The Enhanced Mobility Package EMP Engine requires a special ECM calibration Refer to Engine Control Module ECM processes the various input Control Module ECM Replacement in Engine information The ECM sends the necessary electrical Controls 6 6L LLY in the 2005 C K Truck Service responses to control fuel delivery and other systems Manual and use the ECM Calibrations found in The input information has an interrelation to more than ECM Calibration Chart of this manual 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 The ECM must be reprogrammed using the Enhanced Mobility Package EMP Engine Control Module ECM Calibration Chart 2005 LSSV Service Manual Supplement 6 52 Engine Controls 6 6L LLY Engine BLANK 2005 LSSV Service Manual Supplement Body Table of Contents 8 1 Section 8 Body Body Front End 8 5 Specifications
28. Power to Trailer Relays 2005 LSSV Service Manual Supplement Body 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 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 Remove the radiator grille Refer to Grille Replacement GMC or Grille Replacement Chevrolet in Exterior Trim in 2005 C K Truck Service Manual Remove the filler panel Refer to Radiator Air Baffle and Deflector Replacement Upper in Engine Cooling in 2005 C K Truck Service Manual Trace the auxiliary harness connections to the original harness Remove the connector from the right hand 6 and left hand 5 blackout B O marker lamp Remove the nut to the ground lead and all wiring harness straps connecting the auxiliary harness Remove connector 4 and ground from blackout B O headlamp mounting stud Trace the auxiliary harness under the washer fluid reservoir and remove the wiring harness straps along the fender interior Trace the auxiliary harness under the battery tray area and remove the wrap Remove the forward auxiliary harness 2
29. Service Manual Supplement 8 80 Interior Trim Body Repair Instructions Government Vehicle Data Plate Replacement DATA PLATE Removal Procedure 1 Drill out the 4 rivets 3 2 Remove the data plate 2 1703186 Installation Procedure 1 Install the plate 2 to the original holes 2 Install the new rivets 3 DATA PLATE 1703186 2005 LSSV Service Manual Supplement Body Shipping Data Plate Replacement Removal Procedure 1 Drill out the 4 rivets 3 2 Remove the data plate 1 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 Replacment 2005 LSSV Service Manual Supplement Interior Trim 8 81 DATA DATA PLATE PLATE 1703186 1703186 1703188 8 82 Interior Trim 2 6934 2 6934 1703188 Body 2 Remove floor mat Refer to Carpet Replacement Front in Interior Trim in the 2005 C K Truck Service Manual Installation Procedure 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 2005 C K Truck Service Manual 3 Install gun rack 1 and install bolts Refer to Floor Mount Gun Rack Replacement or Lower Cab Mou
30. Service Manual Supplement Bumpers 8 31 1700943 1700944 8 32 Bumpers 1700946 1700949 1700949 Body 10 Remove the 2 bolts and the 2 nuts from the 11 12 center bumper supporis Using the aid of an assistant remove the bumper assembly from the vehicle Remove the D rings Refer to Front D Ring Replacement Ambulance Maintenance Body or Front D Ring Replacement LSSV in Frame and Underbody Installation Procedure 1 Install the D rings onto the bumper Refer to Front D Ring Replacement Ambulance Maintenance Body or Front D Ring Replacement LSSV in Frame and Underbody Support the bumper assembly by using an approved support system Using the aid of an assistant position the bumper assembly onto the vehicle 2005 LSSV Service Manual Supplement Body Bumpers 8 33 Notice Refer to Fastener Notice in Cautions and Notices 4 Install the 2 bolts and 2 nuts onto the center bumper supports Tighten Tighten the center bumper support bolts to 122 N m 90 Ib ft 1700946 5 Install the 4 bolts onto the lower bumper supports Tighten Tighten the lower bumper support bolts to 77 N m 57 Ib ft 1700944 6 Install the 2 bolts onto the upper bumper supports Tighten Tighten the upper bumper support bolts to 31 N m 23 Ib ft 1700943 2005 LSSV Service Manual Supplement 8 34 Bumpers 1700940 1698255 10 11 12 B
31. Supplement Steering 2 4 Power Steering System Power Steering Pump Heat Shield Replacement Caution Refer to Vehicle Lifting Caution in Repair Instructions Cautions and Notices Removal Procedure Raise the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual 2 Lower the vehicle in order to work through the Jm front wheelhouse opening 3 Remove the power steering pump heat shield bolts 4 Remove the heat shield from the vehicle 1706997 Installation Procedure Install the exhaust manifold heat shield Notice Refer to Fastener Notice in Cautions and Notices 1 Install the exhaust manifold heat shield bolts Tighten 2 1 71 Ib in 3 Lower the vehicle Refer to Lifting and Jacking the Tighten the bolts to 8 N m Vehicle in General Information in the 2005 C K Truck Service Manual 1706997 2005 LSSV Service Manual Supplement Table of Contents 3 1 Section 3 Suspension Suspension Front Suspension 3 3 Specifications 3 3 Fastener Tightening Specifications 3 3 Repair Instructions 3 4 Jounce Shock Absorber Replacement 3 4 Lower Jounce Shock Control Arm Replacement M 3 5 Description and Operation 3 7
32. Symptoms Lighting Systems Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom e Blackout B O Headlamp Inoperative Blackout B O Headlamp Always On Headlamps Operate in Blackout B O Mode e Backup Lamps Inoperative e Voltmeter Gage Lamp Inoperative e Blackout B O Marker Lamps Inoperative e Blackout B O Marker Lamps Always On DRL Operate in Blackout B O Mode e Backup Lamps Operate in Blackout B O Mode e Park Lamps Operate in Blackout B O Mode e CTSY Lamps Operate in Blackout B O Mode Turn Signals Operate in Blackout B O Mode Hi Beam Headlamps Operate in Blackout B O Mode Low Beam Headlamps Operate in Blackout B O Mode e Backup Alarm Always On e Backup Alarm Inoperative 2005 LSSV Service Manual Supplement Body Lighting Systems 8 107 Blackout B O Headlamp Inoperative Step Aiono es NO Schematic Reference Exterior Lights Schematics and Interior Lights Schematics Did you review Blackout B O Lighting Description and Operation Go to Blackout B O Lighting Circuit Go to Step 2 Operation Go to Step 20 Go to Step 3 Inspect condition of fuses If fuse is open locate and repair source of overload and replace fuse Did you find and correct the condition 1 Place blackout B O service switch in blackout B O mode 2 Turn ON blackout B O headlamp switch 3 Connect a test lamp to circuit 901 TN WH at co
33. breaker Installation Procedure 1 Install the 24V 2 or 12V 3 circuit breaker to the fender support with the 4 screws 1 Tip Install 24V circuit breaker with auxiliary contact up 2 Install the wires to the circuit breaker with the two nuts 3 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure 2005 LSSV Service Manual Supplement Engine Circuit Breaker Bracket 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 circuit breakers Refer to Circuit Breaker Replacement 12V or 24V 3 Remove the retainers 1 2 attaching the bracket 3 to the fender cowl support Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 1 Install the bracket 3 to the fender cowl support and tighten the retainers 1 2 Tighten Tighten bracket bolts to 6 N m 53 Ib in Install the circuit breakers Refer to Circuit Breaker Replacement 12V or 24V Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure Battery and Battery Tray Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 2 D Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure Loosen the bolts 1 Push up
34. co co co OW 1692716 3 Trailer Connector NATO 12 Pin 4 License Plate Lamp Legend 1 Blackout B O Marker Stoplamps 2 Trailer Connector Commercial 2005 LSSV Service Manual Supplement Body Lighting Systems 8 101 Rear Lighting Maintenance Body 1692529 Legend License Plate Lamp Blackout B O Marker Stop Lamps Trailer Connector NATO 12 Pin Trailer Connector Commercial 1 Marker Lamps 2 Turn Signal Lamps 3 Tail Stoplamps 4 5 6 7 Backup Lamps 8 a Nr MM a 2005 LSSV Service Manual Supplement 8 102 Lighting Systems Body Rear Lighting Ambulance Body 1692527 Legend 1 Reflectors 3 License Plate Lamp 2 Taillamps with Blackout B O Lamps LED 4 Backup Lamps 2005 LSSV Service Manual Supplement Body Lighting Systems Connector End Views Blackout B O Drive Lamp Switch 1465953 Connector Part 08911352 Information 5 Way F Series 56 BK Circuit Wire Color N O Ras 901 Blackout B O Headlamp Supply Voltage Blackout B O 911 Drive Lamp Switch Supply Voltage 915 Blackout B O Control Relay Signal 2005 LSSV Service Manual Supplement Lighting Systems 8 103 Blackout B O Drive Relay 535912 e 12129716 4 Way F MP Series 280 GY Circuit Wire Color No Blackout B O Headlamp iid Switch Signal Blackout B O Headlamp E Connector Part Information WH Blackout B O Drive Relay Control Voltage B
35. devices or secondary locks 3 Install the 24V relay 1 onto the underhood junction block 4 Secure the wiring harness to the clip 2 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 2005 C K Truck Service Manual 3 Disconnect the generator electrical connector 4 Remove the cable from the output stud 2005 LSSV Service Manual Supplement Engine Electrical 6 31 791846 1704700 395686 6 32 Engine Electrical 660347 395686 660347 Engine 5 Remove the generator bolts 6 Remove the generator from the vehicle Installation Procedure 1 Install the cable onto the output stud of the generator Notice Refer to Fastener Notice in Cautions and Notices 2 Install the nut onto the output stud Tighten Tighten output stud to 9 N m 80 Ib in 3 Install the generator into the mounting bracket 4 Install the generator bolts Tighten Tighten generator bolts to 50 N m 37 Ib ft 5 Connect the generator electrical connector 6 Install the drive belt Refer to Drive Belt Replacement in Engine Mechanical 6 6L in the 2005 C K Truck Service Manual 7 Connect the battery cables Refer to Battery Cable Disconnect Connect Proced
36. easily accessible or visible system components for obvious damage or conditions which could cause the symptom Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions Refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems in 2005 C K Truck Service Manual Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom Gages and Odometer Voltmeter Gage Inaccurate or Inoperative Instrument Cluster Dimming Voltmeter Gage Lamp Inoperative in Lighting Systems Voltmeter Gage Inaccurate or Inoperative Schematic Reference nstrument Cluster Schematics Connector End View Reference nstrument Panel Gages and Console Connector End Views Did you perform the Diagnostic System Check Vehicle 1 Turn the ignition ON with the engine OFF 2 With a DMM measure the voltage of the 24V battery and compare the voltage value with the voltmeter gage display Does the voltmeter gage display approximately the same value as the battery voltage Did you find and correct the condition Test the ground circuit 150 of the voltmeter gage for an open or for a high resistance Did you find and correct the condition Replace the voltmeter gage Refer to Voltmeter Gage Replacement Did you complete the replacement Operate the system in order to verify the repair Did you correct the condition B Test the battery
37. 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 Ib in 4 Slide the front roof bow onto the front struts and install the pins into the bow strut holes 5 Slide the center roof bow on the center struts and install the pins into the bow strut holes 6 Slide the rear roof bow onto the rear struts and install the pins into the bow strut holes 7 Install the strap tensioners to the front and rear top bows by threading them through the retainer loop of the side rail Important The buckle should face inboard 8 Install the front of the cargo cover to the front end rail as needed Refer to Cargo Cover Replacement 2005 LSSV Service Manual Supplement Body Cargo Cover Replacement Removal Procedure 1 Pull apart the velcro corners of the front and rear flaps and roll the cargo cover up over the top 2 Remove the cargo cover from the side rail and end gate retainers by releasing tension and removing hook Pull cover free 3 Untie release or unbuckle all cover retainers 4 Remove the cargo cover Installation Procedure 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 Pr
38. endurance The top of the jounce bumper is mounted to the frame and the lower is mounted to the lower control arm The hydraulic jounce bumper is used in conjunction with the factory jounce bumper 3 8 Rear Suspension Suspension Rear Suspension Specifications Fastener Tightening Specifications Specification Application Jounce Shock Frame Mount Bracket Bolts 53 Ib ft Jounce Shock to Mount Bolt 9 b ft Shock Absorber Cover Bolts 26 Ib ft Shock Absorber Lower Nuts 66 Ib ft 2005 LSSV Service Manual Supplement Suspension 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 4 20 in 0 15 in 10 67 cm 0 15 mm 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 Refer to Rear Jounce Shock Absorber Mount Replacement 2 Remove the nut and bolt 1 from the rear mount 2 3 Remove the jounce shock 3 by sliding it out of the mount 2 Installation Procedure 1 Slide the jounce shock 3 into the mount 2 Notice Refer to Fastener Notice in Cautions and Notices 2 Install the nut and bolt 1 through the mount Tighten Tighten nut and bolt to 12 N m 9 Ib ft 3 Install the rear jounce shock
39. exact locations refer to the 2005 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 Refer to Tire Hoist and Shaft Replacement in Tires and Wheels in the 2005 C K Truck Service Manual EMP vehicles spare tire can be mounted in three different locations depending on vehicle content The locations are as follows n vehicle behind the passenger front seat In the front right corner of the large area e On the rear bumper on a swing away mount Suspension Tires Description The beadlock system can only be used on multiple piece wheels This device fits securely between the tire beads and positively locks the tire to the wheel rim flange Beadlocks allow vehicle operations at the low tire air pressure conditions required for better mobility in mud sand and snow By reducing the air pressure the tire footprint is increased significantly thus allowing a greater area of traction or contact The beadlock also performs as a safety device to insure that the tire does not unseat from the rim or rotate on the wheel at these low air pressure settings while also preventing the entry of foreign objects debris or water into the tire s air chamber It is used in conjunction with the tire pressure mo
40. from the vehicle Remove the wiring harness straps near the bulkhead and disconnect the forward connector of the auxiliary harness from the auxiliary I P harness connector 2005 LSSV Service Manual Supplement Wiring Systems 8 181 1704990 8 182 Wiring Systems 1704990 1703206 Body Installation Procedure 10 11 Connect the forward connector of the auxiliary harness to the auxiliary I P harness connector and attach the tie wraps Install the forward auxiliary harness 2 to the vehicle Install the auxiliary harness under the battery tray area and install the wiring harness straps Install the auxiliary harness under the washer fluid reservoir area and install the wiring harness straps along the fender interior Install the connector to the right hand 6 and left hand 5 blackout B O marker lamp and the ground nut to the ground lead and all wiring harness straps connecting the auxiliary harness Install connector 4 and the ground to blackout B O headlamp mounting stud Install the filler panel Refer to Radiator Air Baffle and Deflector Replacement Upper in Engine Cooling in 2005 C K Truck Service Manual Install the auxiliary harness connections to the original harness Install the radiator grille Refer to Grille Replacement GMC or Grille Replacement Chevrolet in Exterior Trim in 2005 C K Truck Service Manual Connect the batter
41. in the I P relay center From there the OG 40 wire supplies voltage to the blackout B O service switch When the blackout B O service switch is placed in blackout B O mode voltage is applied to the PK 911 wire to inline 5A fuse Voltage is then applied to the BN WH 900 wire for front blackout B O marker lamps and BN WH 900 wire for rear blackout B O marker lamps Ground for the front blackout B O marker lamps is supplied through G100M for the front and G903M and G902M for the rear The blackout B O stoplamps voltage is supplied through the stop LP fuse OG 1540 wire to the TCC stoplamp switch at all times When the brake pedal is depressed the stoplamp switch is closed and powers the WH 17 wire to the blackout B O service switch When in blackout B O mode voltage is applied from the DK GN WH 902 wire to the blackout B O stoplamps The blackout B O stoplamps receive constant ground through G903M and G902M Blackout B O Lighting Description This section focuses on the function and service of the blackout B O headlamp the front and rear blackout B O marker lamps and the service blackout B O lamp switch All other lamps are covered in the 2005 C K Truck Owner Manual As military options the blackout B O lamps provide a stealthy low illumination alternative to standard lighting systems also available on these vehicles The blackout B O headlamp is identical on these vehicles The front black
42. it using the J 42000 before charging Recommended Charging Rates Use the following values when charging the battery Battery Charger 14 8 volts 13 75 amps maximum and 24 hours maximum Until charging amperage is below 0 5 amp Constant Voltage 14 7 to 15 0 volts temperature 122 F 50 C no current limits continue until current falls below 1 amp then finish with 2 amp constant current for 1 hour Float Charge 13 2 to 13 8 volts 1 amp maximum current time indefinite 2005 LSSV Service Manual Supplement Engine Engine Electrical 6 23 Charging Procedure Slave Starting Notice Turn OFF the ignition when connecting or disconnecting the battery cables the battery charger or the jumper cables Failure to do so may damage the PCM or other electronic components 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure 2 Ensure that all of the battery terminals are clean 3 Connect the battery charger per manufacturer s operating recommendations 4 Turn ON the charger and set the charging voltage Refer to Recommended Charging Rates 5 Inspect the battery every half hour after starting the battery Estimate the battery temperature by feeling the side of the battery Tip If it feels hot to the touch or its temperature is over 45 C 125 F discontinue charging and allow the battery to cool before resuming charging 1704708 Inspection Test Optima Batteries contain corro
43. lamp at cavity C of the blackout B O switch and ground Does the test lamp illuminate Go to Step 3 Go to Step 6 1 Disconnect the blackout B O service switch connector from the switch 2 Connect a test lamp at cavity C of the connector and ground Does the test lamp illuminate Go to Step 5 Go to Step 4 Locate and repair the short to voltage on circuit 912 OG pv Did you complete the repair Go to Step 9 Remove the backup lamp interrupt relay from the relay module La see D yo e cms Did you complete the replacement Go to Step 9 Locate and repair the short to voltage on circuit 1969 BK WH ew ia Did you complete the repair Go to Step 9 Operate the system in order to verify the repair un l m Did you correct the condition System OK Go to Step 2 Low Beam Headlamps Operate in Blackout B O Mode Step 1 Adl No Schematic Reference Exterior Lights Schematics and Interior Lights Schematics Did you review Blackout B O Lighting Description and Operation Go to Blackout B O Lighting Circuit Go to Step 2 Operation 1 Place the blackout B O service switch in blackout B O mode 2 Connect a test lamp at cavity C of the blackout B O switch and ground Does the test lamp illuminate Go to Step 3 Go to Step 6 1 Disconnect the blackout B O service switch connector from the switch 2 Connect a test lamp at cavity C of the connector and ground Does the test lamp illu
44. receivers to be carried out very easily 2005 LSSV Service Manual Supplement Suspension Learn Mode Calibration 1 Turn ON the ignition with the engine OFF 2 Apply the parking brake Important Install the sensors on the wheels Refer to Tire Pressure Monitor Sensor Replacement lt sensors are already installed on the vehicle make sure the vehicle is stationary for 20 minutes before proceeding to step 3 3 Turn ON the initiator ensure the LED is green 4 Enter Level 2 Programming Mode Refer to Tire Pressure Monitoring Sensor Programming 5 Press the MODE button to select learn mode which is indicated by a head with a question mark icon 6 Press the TIRE button to display the possible wheel positions for the towing vehicle a windshield can also be seen to indicate that the towing vehicle is selected The outline of the wheel position to be programmed will flash If a sensor already exists in this position the tire icon is filled in it is recommended to remove the sensor by pressing the MODE button 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 oc
45. the SET button to save and exit this mode Important If more than one tire location contains the same sensor number the display will prompt an error with the conflicting tires filled in and the associated sensor number 8 Press any button to return the tire selection menu and make necessary corrections 2005 LSSV Service Manual Supplement Tire Pressure Monitoring 3 45 1641557 1641558 3 46 Tire Pressure Monitoring Suspension Important I his display indicates that ID 1 is programmed in two locations causing the error 9 Press the SET button again to revert to normal mode 1641560 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 Press the TIRE button to scroll to the desired axle the tires of the selected axle are filled in 3 Press the MODE button to display the current value of slope for the selected axle 1641561 4 Press the TIRE button to increase the value 5 Press the MODE button to decrease the value The minimum value is 10 and the maximum is 160 6 Press the SET button to save the value
46. the accessory panel 2 onto the dash Notice Refer to Fastener Notice in Cautions and Notices 6 Install the fasteners 1 and tighten Tighten Tighten accessory panel bolts to 8 N m 71 Ib in Air Filter Restriction Gage Replacement Removal Procedure 1 Remove the accessory panel Refer to Accessory Instrument Panel LH Replacement 2 Remove the air line 2 from the gage 1 3 Remove the screws 1 that retain the gage 2 to the instrument panel 4 Remove the gage from the accessory panel 2005 LSSV Service Manual Supplement Instrument Panel Gages and Console 8 73 1694852 1693472 1693481 8 74 Instrument Panel Gages and Console Body Installation Procedure 1 Install the gage to the accessory panel 2 Install the screws 1 that retain the gage 2 to the instrument panel Tighten the screw until fully seated 1693481 3 Install the air line 2 to the gage 1 4 Install the accessory panel Refer to Accessory Instrument Panel I P Replacement 1693472 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 1694858 2005 LSSV Service Manual Supplement Body Instrument Panel Gages and Console 8 75 3 Remove the lower bolts 1 of the instrument panel 2 4 Pull the I P cluste
47. the adapter 3 2005 LSSV Service Manual Supplement Instrument Panel Gages and Console 8 77 1 2 1694858 1694858 1694858 8 78 Instrument Panel Gages and Console Body Description and Operation Instrument Panel I P Gages Air Filter Restriction Gage Description 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 Some modifications have been made to the instrument panel to accommodate auxiliary harness connections and convenience fuse centers 1694861 The air filter restriction gage is located in the accessory trim panel on the lower center of the instrument panel It monitors the engine air filter As the filter gets dirty the yellow indicator will begin to rise When it reaches the top of the scale the filter should be replaced After replacing the filter reset the gage by pressing in the yellow reset button 1 at the bottom of the gage 2005 LSSV Service Manual Supplement Body Interior Trim 8 79 Interior Trim Specifications Fastener Tightening Specifications Specification Application _ Eih 35 Nm 55 Nm 20 Nm 53 Nem I3 Nm Pionner Tool Kit Bracket Bolts Co Z 3 2005 LSSV
48. the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2 Remove the negative cable 3 from the junction block 3 Remove the positive cable 1 from the junction block 2 2005 LSSV Service Manual Supplement Engine 4 Remove the wiring harness straps securing the cable Remove the clamp bolt and clamp from cable Remove the bolt 1 securing cable connector to the bracket Remove the cable 2 from the vehicle Note cable routing for installation 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 Ib ft Install the clamp and secure with bolt Working from the rear to the front of the vehicle install the wiring harness straps Install the positive cable 1 to the junction block 2 Install the negative cable 3 to the junction block 2 Tighten Tighten the junction block nuts to 34 N m 25 Ib ft Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure 2005 LSSV Service Manual Supplement Engine Electrical 6 41 1707430 1707430 1707377 6 42 Engine Electrical Engine Rear Winch Harness and Connector Replacement Maintenance Body Removal Procedu
49. the nuts 1 and the ground connector 2 from the marker lamp 1693474 2005 LSSV Service Manual Supplement Body Lighting Systems 8 129 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 1707690 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 marker lamp nuts to 2 N m 18 Ib in 3 Install the harness connector 3 to the marker lamp connector 4 Secure the harness in the original mounting location using the wiring harness strap 4 1693474 2005 LSSV Service Manual Supplement 8 130 Lighting Systems Body Rear Marker Lamp Replacement Maintenance Body Removal Procedure Important The bulbs in the marker lamps are not replaceable and are serviced as an assembiy 1 Ensure that the headlamp switch is in the OFF position 2 Using your hands peel the lens out of the rubber gasket 3 Disconnect the wire harness from the back of the lens 1693480 Installation Procedure 1 Connect the wire harness onto the lamp 2 Install the lens into the rubber gasket 3 Ensure that the lens is fully installed in the gasket 1693480 Blackout B O Taillamp Replacement LSSV Removal Procedure 1 Ensure all lamp switches are in the OFF position 2 Remove the wiring harness strap fr
50. trailer wiring harness from the rear bumper Refer to 12V and 24V Harness Replacement Maintenance Body in Wiring Systems 7 Remove the marker lamps Refer to Rear Marker Lamp Replacement Maintenance Body in Lighting Systems 1693480 8 Remove the taillamps 1 Refer to Taillamp Replacement Maintenance Body in Lighting Systems 9 Remove the blackout B O marker lamps 2 Refer to Rear Marker Lamp Replacement Maintenance Body in Lighting Systems 10 Remove the 12 pin trailer connector 4 Refer to Military Trailer Connector Replacement LSSV or Military Trailer Connector Replacement Maintenance Body in Lighting Systems 11 Remove the commercial trailer connector 3 Refer to Commercial Trailer Connector Replacement LSSV or Commercial Trailer Connector Replacement Maintenance Body in Lighting Systems 1702052 Installation Procedure 1 Install the marker lamps Refer to Rear Marker Lamp Replacement Maintenance Body in Lighting Systems 1693480 2005 LSSV Service Manual Supplement 8 42 Bumpers 1702052 1700950 1698269 Body Install the taillamps 1 Refer to Taillamp Replacement Maintenance Body in Lighting Systems Install the blackout B O marker lamps 2 Refer to Rear Marker Lamp Replacement Maintenance Body in Lighting Systems Install the 12 pin trailer connector 4 Refer to Military Trailer Connector Replacement LSSV or Military Trail
51. voltage circuit of the voltmeter gage for an open 3 for a short to ground or for a high resistance p Go to Diagnostic System Check Vehicle in Vehicle DTC Information in 2005 C K Truck Go to Step 2 Service Manual Go to 24V Generator Inoperative Go to Step 3 Go to Step 6 Go to Step 4 Go to Step 6 Go to Step 5 Go to Step 6 NEM oystem OK Go to Step 2 2005 LSSV Service Manual Supplement Body Instrument Panel Gages and Console 8 71 Repair nstructions Voltmeter Gage Replacement Removal Procedure Caution Refer to Battery Disconnect Caution 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 LH Replacement 3 Remove the nuts 4 from the back of the voltmeter 4 Remove the voltmeter gage bracket 3 and remove the voltmeter 1 from the panel 1694856 Installation Procedure 1 Install the voltmeter 1 into the panel opening 2 Install the bracket 3 on the back of the voltmeter Notice Refer to Fastener Notice in Cautions and Notices 3 Install the nuts 4 on the voltmeter gage studs Tighten Tighten nuts to 2 8 N m 24 Ib in 4 Install the accessory panel Refer to Accessory Instrument Panel 1 P Replacement 5 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 1694856 2005 LSSV Service Manua
52. with a safety strap which should be hooked across the rear end of the box when occupied Refer to the 2005 LSSV Owners Manual Supplement for further details Seat Covers Seat covers are installed on the interior seats to protect the vehicle s interior and are green or tan in color They allow full function of the seat controls and seat belts 2005 LSSV Service Manual Supplement Body Wiring Systems 8 147 Wiring Systems Specifications Fastener Tightening Specifications Specification Application Metric English Schematic and Routing Diagrams 2005 LSSV Service Manual Supplement jueuiejddng jenuey 891449S ASST 5002 Power Distribution Schematics 12V 24V 1 L RD C 32 S swa shs DuuIM 8rL 8 900 1 RD RD 8 32 1 RD 32 o bd 12V 24V Vehicle m m mic Load m Disconnect O 1 or Uz Switch Junction RD 7 Block 32 900 Rear RD Winch 13 Fuse T Block RD Underhood 8009 32 ood RD BK 8 8004 C RD po Ml Ji T Battery L J Cable S103M 5 8009 BK WH Fusible RD BK 8 Link 2 Fusible S104M Link 8009 8009 8009 L 1 Generator rola 1 Generator RD BK RD BK RD BK I Left l Left 0 8 2 0 8 d s oe i 87 A A mu OTT Relay 24V 24V 124V Fuse Trailer i Generator 25A Fuse I I 25A WwW O 1704597 lae jueuiejddng enuejy 891449 ASST 5002 Power Distribution Schematics 24V Trailer Fuse 24V W LOAD SWITCH ON o 24V Trailer Fuse
53. 005 LSSV Service Manual Supplement Body Wiring Systems 8 165 Underhood Relay Block Blackout B O Lighting 1693357 Legend 1 Turn Signal Relay 5 Headlamp Low Beam Relay 2 Park Lamp Relay 6 DRL Relay 3 Headlamp Hi Beam Relay 7 Horn Relay 4 Interrupt Wiring Harness 2005 LSSV Service Manual Supplement 8 166 Wiring Systems Body 12V and 24V Circuit Breakers Ambulance 1703354 Legend 1 50 amp 24V Circuit Breaker 3 120 amp 12V Circuit Breaker 2 Circuit Breaker Bracket 4 Screws 2005 LSSV Service Manual Supplement Body Wiring Systems 8 167 24V Trailer Fuse 24V Accessory Fuse 350882 350882 Connector Part e 12010105 Connector Part e 12010105 Information 2 Way F Auto Fuse Holder Information 2 Way F Auto Fuse Holder Circuit Circuit Wire Color N Wire Color No A RD BK 8009 24V Battery Voltage A RD BK 8009 24V Battery Voltage O Trailer Connector B RD GY 8009 24V Feed Not Used RD WH 802 Supply Voltage Inline Harness Connector End Views C100M Front Blackout B O Harness to Blackout B O Marker Lamp 1391785 1708840 Connector Part e 12015791 Connector Part e 12010996 Information e 1 Way F Weather Pack BK Information 1 Way M Weather Pack BK Circuit Circuit Wire Color No Wire Color No Blackout B O Marker Blackout B O Marker 2005 LSSV Service Manual Supplement 8 168 Wiring Systems Body C101M Front Blackout B O Harness to Blackout B O Marker La
54. 04595 Legend 1 C902M 5 C908M 2 License Plate Lamp 6 C900M 3 Trailer Lighting Relays 7 C901M 4 C903M 2005 LSSV Service Manual Supplement 8 160 Wiring Systems Body Component Locator Master Electrical Component List Connector End View Engine Electrical 24V e E SM jd side of the bumper Component Views in y g Engine Electrical Engine Electrical Engine Electrical 24 Voltmeter Gage Lamp BAN d oe panel on the Component Views in Connector End Views Engine Electrical in Engine Electrical Backup Lamp Relay indi the interrupt harness under Be e Engine Electrical Lighting Systems Blackout B O Drive Relay Inline on the auxiliary I P harness Component Views in Connector End Views Engine Electrical in Lighting Systems Lighting Systems Lighting Systems Blackout B O Headlamp sil iis e m of the bumper Component Views in Connector End Views 9 Lighting Systems in Lighting Systems Blackout B O Lighting Systems Lighting Systems Marker bam TE In the left side of the front bumper Component Views in Connector End Views P Lighting Systems in Lighting Systems Blackout B O Lighting Systems Lighting Systems Ta T In the right side of the front bumper Component Views in Connector End Views is P Lighting Systems in Lighting Systems Lighting Systems Lighting Systems S het is prp as ala ONIS Component Views in Connector End Views ki a e atleti ed Lighting Systems in Lighting Systems Blackout B O Lighting System
55. 05 C K Truck Service Manual 2 Remove the tire and wheel Refer to Tire and Wheel Removal and Installation in Tires and Wheels in 2005 C K Truck Service Manual 3 Remove the jounce shock absorber Refer to Jounce Shock Absorber Replacement 4 Remove the 2 control arm brace bolts 1 Remove the control arm pivot bolt 2 and washer O1 1700951 Remove the control arm brace 2 Remove the outer shim 1 Remove the control arm 3 Inspect both shims 1 and pivot nut 4 Replace if worn c CON O 1700954 Installation Procedure 1 Install the inner shim 1 and control arm 3 onto the pivot nut 4 1700954 2005 LSSV Service Manual Supplement 3 6 Front Suspension 1700955 1700951 2 3 Suspension 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 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 Tighten Tighten bolts to 72 N m 53 Ib ft Install the washer and pivot bolt 2 Tighten Tighten bolt to 244 N m 180 Ib ft Verify the control arm pivots freely and that the final alignment is c
56. 0616 1700620 Body Rear Frame Bracket Replacement Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices Raise the vehicle Refer to Lifting and Jacking the Vehicle in General Information in the 2005 C K Truck Service Manual Remove the rear skid plate Refer to Rear Skid Plate Replacement Remove the rear support beam Refer to Rear Support Beam Replacement Remove the nuts 3 and bolt 1 Remove the rear mounts 2 and 4 Installation Procedure ils Install the rear mounts 2 and 4 Notice Refer to Fastener Notice in Cautions and Notices Install the bolts 1 and nuts 3 Tighten Tighten nuts and bolts to 35 N m 26 Ib ft Install the rear support beams Refer to Rear Support Beam Replacement Install the rear skid plate Refer to Hear Skid Plate Replacement Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in the 2005 C K Truck Service Manual Fuel Tank Skid Plate 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 2005 C K Truck Service Manual Support the fuel tank cover Remove the cover bolts 2 Remove the inner cover bolts 1 2005 LSSV Service Manual Supplement Body 5 Remove the outer front cover bolts 1 from the s
57. 24 Bar Option Package EMP Enhanced Mobility Package vehicles only Non EMP vehicles refer to the Tire and Loading Information label attached to the vehicles center pillar B pillar below the driver s door lock post striker Inflation pressure needed to obtain the Gross Vehicle Weight Rating GVWR All Axles 2005 LSSV Service Manual Supplement 0 8 Maintenance and Lubrication General Information Tire Pressure Monitoring System Settings EMP Only Tire Pressure and Slope Cold Inflation Pressure Highway Front Axle 45 PSI 3 10 Bar Highway Rear Axle 65 PSI 4 48 Bar Cross Country 23 PSI 1 60 Bar Highway 40 PSI 2 76 Bar Mud Sand Snow 18 PSI 1 24 Bar Spe Tire Pressure Alerts and Warnings Deviation Pressure Alert Low Pressure Warning Highway Front Axle 5 PSI 0 34 Bar 33 PSI 2 28 Bar Highway Rear Axle 5 PSI 0 34 Bar 40 PSI 2 76 Bar Cross Country 5 PSI 0 34 Bar 30 PSI 2 07 Bar 17 PSI 1 17 Bar Highway 5 PSI 0 34 Bar Mud Sand Snow 5 PSI Factory Tire Pressure Setting All Axles From Cold Pressure Tire Setting Maintenance Items The Normal Maintenance Replacement Parts information will be found in the Owners Manual and Owners Manual Supplements Refer to the Maintenance Schedule subsection of the Owners Manual Maintenance Maintenance Schedule The Maintenance Schedule information will be found in the Owners Manual an
58. 25A B 802 RD WH 2 C110M A 802 RD 2 C909M A t 8 802 RD 2 S908M 802 802 802 802 802 RD RD RD RD RD 2 2 2 2 2 87 87 87 L 87 L 87 Park Left Right T Left 1 M Right Relay l Turn j Turn l Trailer l Trailer i Signal Signal Blackout i Blackout l l Relay l Relay l Relay i Relay 1704600 Apog 6pl g suiejs S uM jueuiejddng jenuey 891449S ASST 5002 Power Distribution Schematics Relay Block e Relay O Block 2 l i I P I i la e 1 C8 C S303M 912 Blackout yr j Service OG N Blackout Switch 1 ACC OFF A 86 k 86 86 4 86 86 A 86 Interrupt Relay 1 uon 13 pn 7 Low 1 uap 1 park lM un Block I l I 1 c Relay i Relay EE i i Siah Relay Ens l I l y 988 7 prey j yey i po l i l ka mm m a wd ka mm m mm wd ka mm d ka mm d la ai la ai J 1704602 suiejs s BUNA 09 L 9 U O Q lt jueuiejddng enuey 891449 ASST 5002 Blackout Marker Lamp Left 151 0 8 Front Ground Distribution Schematics G100M G101M G102M x Blackout WV Headlamp 151 BK 8100M 151 BK G100M I Blackout E Y Marker I Lamp 7 Right Front 151 0 8 J Relay I Generator I 24V l 151 BK G101M T Slave l Start Rece
59. 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 Notice Refer to Fastener Notice in Cautions and Notices 5 Ensure that the contact pad of the jounce shock is aligned with the jounce shock Tighten e Tighten lower shock bolt to 90 N m 65 Ib ft Tighten shock cover bolts to 35 N m 26 Ib ft 6 Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual 2005 LSSV Service Manual Supplement 1700959 1700959 1700958 3 12 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 2005 C K Truck Service Manual Remove bolts 6 and nuts 4 from the cover Remove bolt 2 from the shock cover Remove nut 3 and bolt 8 from the shock Remove shock covers pieces 1 5 7 from the axle housing CI c rn 1700957 Installation Procedure 1 Install the shock cov
60. 449S ASST 5002 Exterior Lights Schematics Blackout B O Light Controls r i i i L C1 Fuse i Block i Left H P B8 913 WH 1 T Blackout Service Switch I I I I 17 WH 902 7 D GN WH 0 8 A r7 Stop i Lamp i Switch V 1 L L m m m w 901 BN WH 1 30 Blackout Drive Relay 87 85 911 901 PK TN WH 1 1 S307M S304M 911 PK 1 901 TN WH 1 Ground 150 Distribution Schematics in Wiring Systems V WV G304M r FM 1693289 suejs s DunuDr1 26 8 pog jueuiejddng enuey 891449 ASST 5002 77772 Park Lamp i Relay i Las 915 1 0 Exterior Lights Schematics Exterior Lighting V KE Y 901 TN WH 1 0 B License Piate Lamp C102M 4A Blackout Headlamp 151 1 0 Schematics in Wiring Systems Ground Distribution 911 PK 1 0 B 901 902 TN WH D GN WH 0 8 A 0 8 900 BN WH 900 BN WH 0 8 0 8 900 BN WH 1 0 C103M LAR 8 S313M C108M4A jB 900 902 BN WH D GN WH S102M 0 8 0 8 900 BN 0 8 C101M T A C100M7 A 902 D GR WH 0 8 Blackout Blackout k pres BHP ane son nn os LE RF S901M S902M 902 GN WH 0 8 4 900 ena BN WH 0 8 0 8 J5 C903M AA A B C902M ABA A BK BK Blackout 0 8 0 8 Marker Lamp LR 902 GN WH S100M 08 151 NEN BK 1 0 G100M G903M G902M ye o Q m Mu tI V 900 BN WH 0 8 Blackout Marker Lamp RR 1693290 Apog 6 3 Ssuajs4s uny jueuiejddng
61. 6 22 Battery Inspection Test Optima 6 22 Battery Charging Optima 6 22 Jump Starting in Case of Emergency 6 23 24V Generator Noise Diagnosis 6 25 24V Generator Inoperative 6 26 Repair Instructions 6 28 Circuit Breaker Replacement 12V or 24V 6 28 Circuit Breaker Bracket Replacement 6 29 Battery and Battery Tray Replacement 6 29 Relay Replacement 24V Generator 6 30 24V Generator Replacement 6 31 Battery Cable Disconnect Connect OC COURS MN SAN YMM EM ES 6 33 2005 LSSV Service Manual Supplement Vehicle Load Disconnect Switch Replacement LSSV Maintenance Body 6 34 Vehicle Load Disconnect Switch Replacement Ambulance 6 36 12V Battery Positive Cable Replacement Battery to Battery 6 37 12V Battery Negative Cable Replacement Frame Mounted Battery 6 38 Front Winch Harness and Connector Replacement 6 39 Rear Winch Harness and Connector Replacement LSSV 6 40 Rear Winch Harness and Connector Replacement Maintenance Body 6 42 Slave Receptacle Harness Replacement Ambulance Maintenance Body 6 43 Slave Receptacle Harness Replacement LS
62. 900 24V Power Supply Winch Prep Connector Front Connector Part Information RD BK 1703366 Connector Part e TX017639 Information 2 Way RD Circuit Wire Color No B 6 22 Engine Electrical Winch Prep Connector Rear amp D 1703366 Connector Part e TX017640 Information e 2 Way RD a Wire Color A mou E M e ek n Ground 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 Refer to Symptoms Engine Electrical in order to identify the correct procedure for diagnosing the system and where the procedure is located Symptoms Engine Electrical Symptom List Important For vehicle no start condition refer to Diagnostic Starting Point Engine Electrical and for Starter Motor Diagnosis refer to Symptoms Engine Electrical in Engine Electrical in 2005 C K Truck Service Manual Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom 24V Generator Noise Diagnosis 24V Generator Inoperative e Battery Inspection Test Optima e Batt
63. A B 803 800 BN BN WH 11 0 1 0 A B Topper Lamp Switch Topper Dome Switch G904M p 4 T 1693284 suejs s uny 96 8 U O Q lt jueuiejddng enuey 891449 ASST 5002 Interior Lights Dimming Schematics Apog m F 690 ii Relay GY BK 0 35 61 68 GY C624 CM poner ha 1 8257 6 BN 1 ee Ground C5CNE 1 C5 6GY C10 12NA I dP r M LZ Depp o J Ed I i Body J ae el Courtesy s Module i Lamp Supply i BCM Voltage I Class2 I zs i 9 ata lae e mcd ch md cid d Cum cds e C ed dab mmi d am i l BN 0 8 9 BN 0 8 A TPM System Voltmeter Schematics in Gage Tire Pressure Lamp Monitoring B 16 3 suiejs g Bunybry 1693286 8 98 Lighting Systems Body Component Locator Lighting Systems Component Views Front Lighting LSSV 1692532 Legend 1 Blackout B O Marker Lamps 2 Blackout B O Headlamp 2005 LSSV Service Manual Supplement Body Lighting Systems 8 99 Front Lighting Ambulance Maintenance Body 1693355 Legend 1 Blackout B O Headlamp 5 Marker Lamps 2 Headlamp Harness Connector 6 Headlamp Fastening Nut 3 Blackout B O Marker Lamp Fastening Nuts 7 Washer 4 Marker Lamp Harness Connector 8 Headlamp Ground Lead 2005 LSSV Service Manual Supplement Body Rear Lighting LSSV 8 100 Lighting Systems co co
64. ANK 2005 LSSV Service Manual Supplement Driveline Axle Section 4 Driveline Axle Front Drive Axle 4 3 Repair Instructions 4 3 Front Axle Vent Tube Filter Replacement 4 3 Description and Operation 4 3 Front Axle Vent Tube Filter Description 4 3 Rear Drive Axle 4 4 Repair Instructions 4 4 Rear Axle Vent Tube Filter Replacement 4 4 2005 LSSV Service Manual Supplement Table of Contents 4 1 Description and Operation Rear Axle Vent Tube Filter Description Transfer Case NVG 261 NP2 Repair Instructions Transfer Case Vent Tube Filter Replacement Description and Operation Transfer Case Vent Tube Filter Description 4 2 Table of Contents Driveline Axle BLANK 2005 LSSV Service Manual Supplement Driveline Axle 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 pip
65. 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 Remove the bolts 1 from the winch connector 2 6 Remove connector harness from vehicle Note cable routing for installation 2005 LSSV Service Manual Supplement Engine Electrical 6 39 1703365 1706660 1710976 6 40 Engine Electrical 1710976 1706660 1707377 Engine Installation Procedure 1 Install connector harness to the vehicle in the same routing as removed Notice Refer to Fastener Notice in Cautions and Notices 2 Position the connector 2 on the bumper and install bolts 1 Tighten Tighten the connector bolts to 10 15 N m 7 11 Ib ft 3 Install the negative cable to the engine and the fastening bolt Tighten Tighten the negative cable bolt to 34 N m 25 Ib ft 4 Install the positive cable 1 to the junction block 2 Tighten Tighten the junction block nut to 9 N m 80 Ib 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 Rear Winch Harness and Connector Replacement LSSV Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect
66. Caution in Cautions and Notices 1 Raise the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual Remove the brace bolt 3 Remove the plastic retainer 1 Remove the screws 2 Remove the mud guard 4 from the vehicle CI BEM Installation Procedure 1 Install the mud guard 4 to the vehicle 2 Install the plastic retainer 1 Notice Refer to Fastener Notice in Cautions and Notices 3 Install the brace bolt 3 Tighten Tighten the brace bolts to 25 N m 18 lb ft 4 Install the screws 2 Tighten Tighten the screws to 4 N m 35 Ib in 5 Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual Description and Operation Exterior Trim Description Mud Guards These vehicles may be equipped with mud guards at the front of the rear wheel openings to prevent brake damage when exposed to off road conditions 2005 LSSV Service Manual Supplement Exterior Trim 8 47 1707323 1707323 8 48 Frame and Underbody Body Frame and Underbody Specifications Fastener Tightening Specifications Specification Application Engin ZON 85 Nem SONUM 200 Nm 8797 Nm 50 Nem 29 Nm 20 Nm EN 85 Nem BESEN ZON SON 200 Nm 37 NT 120 Nm 90 Nem 54 46 Nm 2534 bf SEN EN 85 Nem BEN IT 2005 LSSV Service Manual Supplement Body Frame and Underbody 8 49
67. Connect Procedure 2005 LSSV Service Manual Supplement Engine Electrical 6 35 1704706 1704707 1704703 6 36 Engine Electrical Engine Vehicle Load Disconnect Switch Replacement Ambulance 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 disconnect switch key 1 from the switch 2 1703362 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 Oo BW 1703363 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 Tighten Tighten the cable mounting nuts to 9 N m 80 Ib in Red cable from 24V battery positive 1 to terminal 4 Red black cable 4 from 24V generator to terminal 3 Red cable 3 from UBEC to terminal 1 Red cable 2 from 24V battery negative to terminal 2 1704706 2005 LSSV Service Manual Supplement Engine Engine Electrical 6 37 2 Install the switch cable cover 3 3 Install the switch cable cover mounting screws 2 Tighten Tighten the switch cable cover mounting screws to 1 6 N m 14 Ib in
68. Connect the heater cord to the coolant heater ASN CAN RA v e 7 6 Remove the right engine mount Refer to Engine MM KA IMA KDR NV EY Mount Replacement Right in Engine Mechanical NK limp ENG 7 6 6L LLY in 2005 C K Truck Service Manual 7 Install the right front tire and wheel Refer to Tire and Wheel Removal and Installation in Tires and Wheels in 2005 C K Truck Service Manual 8 Fill the cooling system Refer to Draining and Filling Cooling System Ambulance Body 2 c Qa RN yz 9 Inspect for coolant leaks we TE 674570 2005 LSSV Service Manual Supplement Engine Engine Cooling 6 9 Special Tools and Equipment L WMusmaton Tool Number Description J 26568 Coolant and Battery Tester J 38185 Hose Clamp Pliers 2005 LSSV Service Manual Supplement 6 10 Engine Electrical Engine Engine Electrical Specifications Fastener Tightening Specifications Application Merc Engin Battery Usage Optima Battery Charging Specifications Optima Cold Cranking 750A Amperage CCA 13 8 V to 15 0 V Reserve Capacity Rating 27 V to 32 V Generator Usage EA Battery Charger 13 75 A 12V Amps Battery Charger Time 24 Hours Maximum Constant Voltage Charging Constant Voltage Volts 14 7 V to 15 0 V Constant Voltage 122 F 50 C Temperature Constant Voltage Amps Constant Voltage Time Charging falls below 1 A then 2 A for 1 hour Float Charge 13 2 V to 13 8 V
69. D Ring Bracket Replacement LSSV in Frame and Underbody Remove the rear blackout B O taillamps 1 Refer to Blackout B O Taillamp Replacement LSSV or Blackout B O Taillamp Replacement Maintenance Body in Lighting Systems 2005 LSSV Service Manual Supplement Body Bumpers 8 43 5 Remove the license plate lamp 2 Refer to License Plate Lamp Replacement LSS V or License Plate Lamp Replacement Maintenance Body or License Plate Lamp Replacement Ambulance Body in Lighting Systems 6 Remove the license plate bracket 1 Refer to License Plate Bracket Replacement 7 Remove the rear step pad if equipped Refer to Step Pad Replacement Rear Bumper 1698272 8 Remove the 24V trailer connector 3 Refer to Military Trailer Connector Replacement LSSV or Military Trailer Connector Replacement Maintenance Body in Lighting Systems 9 Remove the 12V trailer connector 1 Refer to Commercial Trailer Connector Replacement LSSV or Commercial Trailer Connector Replacement Maintenance Body in Lighting Systems 10 Remove the rear winch power disconnect 2 if equipped Refer to Rear Winch Harness and Connector Replacement LSSV or Rear Winch Harness and Connector Replacement Maintenance Body in Engine Electrical 1698270 11 Remove the rear relay mounting bracket from the bumper 12 Remove the rear lamp wiring harness Refer to Lamp Harness Replacement Rear LSSV or Lamp Harness Re
70. Engine Electrical 2005 LSSV Service Manual Supplement Body Wiring Systems 8 161 Master Electrical Component List cont d Locator View Engine Elecirical Horn Interrupt Relay G e OGOR 1 Component Views in p Engine Electrical Engine Elecirical Interrupt Relay Block ll ap on the Component Views in Engine Electrical Engine Electrical Junction Block si sin battery mounted on the Component Views in Engine Electrical Engine Electrical Park Lamp Interrupt Relay d eal D ER A engine Component Views in cour Engine Electrical Lighting Systems Lighting Systems Trailer gt Connector Near the center of the rear bumper Component Views in Connector End Views a Lighting Systems in Lighting Systems Lighting Systems Component Views in Lighting Systems Connector End View Interrupt relay block RH engine Turn Signal Interrupt Relay compartment Front left of the front bumper for left front s Inline Harness OR AVIY blackout B O marker hamess Routing Views Connector End Views Front right of the front bumper for right Inline Harness C101M 1 Cavity front blackout B O marker Harness Houling Views Connector End Views C102M 1 Cavity eae of grille for blackout B O Harness Routing Views Rd Uu M Inline Harness Connector End Views Inline Harness Connector End Views Inline Harness Connector End Views Inline Harness Connector End Views Inline Harness Connector End Views Inline Harness Connector End Views In
71. Front Enhanced Suspension 3 7 Front Hydraulic Jounce Bumper Description 3 7 Rear Suspension 3 8 Specifications aii oe todo eee 3 8 Fastener Tightening Specifications 3 8 Repair Instructions 3 9 Rear Jounce Shock Absorber Replacement og Rear Jounce Shock Absorber Mount Replacement 3 10 Shock Absorber Cover Replacement Left 3 10 Shock Absorber Cover Replacement Right 3 12 Description and Operation 3 13 Rear Enhanced Suspension 3 13 Rear Shock Absorber Description 3 13 Rear Shock Absorber Cover Description 3 13 Rear Hydraulic Jounce Bumper 3 13 Tires and Wheels 3 14 Specifications serseri anma yaaa li halan 3 14 Fastener Tightening Specifications 3 14 Componentlocator 3 15 Tires and Wheels Component Views 3 15 Repair Instructions 3 16 Tire Mounting and Dismounting Beadlock T A 3 16 Spare Tire Carrier Replacement In Vehicle see eee eee 3 22 Spare Tire Carrier Replacement Bed Mounted 3 23 Spar
72. Go to Step 2 2005 LSSV Service Manual Supplement 8 114 Lighting Systems Body Backup Lamps Operate in Blackout B O Mode Schematic Reference Exterior Lights Schematics and Interior Lights Schematics Did you review Blackout B O Lighting Description and Operation Go to Blackout B O Lighting Circuit Go to Step 2 Operation 1 Place the blackout B O service switch in blackout B O mode 2 Connect a test lamp at cavity C of the blackout B O switch and ground Does the test lamp illuminate Go to Step 3 Go to Step 6 1 Disconnect the blackout B O service switch connector from the switch 2 Connect a test lamp at cavity C of the connector and ground Does the test lamp illuminate Go to Step 5 Go to Step 4 Locate and repair the short to voltage on circuit 912 OG pv Did you complete the repair Go to Step 9 Remove the backup lamp interrupt relay from the relay module La see D yo comper e replacment espe Did you complete the replacement Go to Step 9 Locate and repair the short to voltage on circuit 24 GN BK ew ia Did you complete the repair Go to Step 9 Operate the system in order to verify the repair m mumu Did you correct the condition System OK Go to Step 2 Park Lamps Operate in Blackout B O Mode Step 1 Actio No Schematic Reference Exterior Lights Schematics and Interior Lights Schematics Did you review Blackout B O Lighting Description
73. Important Do not discharge the internal pressure of the jounce shock The loss of oil during discharge may affect the performance setting 1 Raise the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual 2 Remove the tire and wheel Refer to Tire and Wheel Removal and Installation in Tires and Wheels in 2005 C K Truck Service Manual 3 Remove the lower shock nut and bolt 2 4 Remove the upper shock nut and bolt 1 5 Remove the jounce shock 3 from the vehicle Installation Procedure 1 Install the jounce shock 3 onto the vehicle Ensure that the pressure fitting is facing the outside of the vehicle Notice Refer to Fastener Notice in Cautions and Notices 2 Install the upper nut and bolt 1 Tighten Tighten bolt to 125 N m 92 Ib ft 3 Install lower nut and bolt 2 Tighten Tighten bolt to 125 N m 92 Ib ft 4 Install the tire and wheel Refer to Tire and Wheel Removal and Installation in Tires and Wheels in 2005 C K Truck Service Manual 5 Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual 2005 LSSV Service Manual Supplement Suspension Front Suspension 3 5 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 20
74. Important Repeat steps 2 6 until the slope level is set for all axles desired d d 7 Press the SET button to exit 8 Press the SET button again to revert to normal mode 1641562 2005 LSSV Service Manual Supplement Suspension Learn Mode Important This mode is used to add or remove transmitters from the system Learn Procedure W O Special Tool 1 2 Enter Level 2 Programming Mode Refer to Entering Programming Modes Press the MODE button to select the learn mode icon Press the TIRE button to display the ten possible wheel positions for the towing vehicle The currently installed transmitter positions are now indicated with a filled in tire indicator Use the TIRE button to scroll to the desired position The outline of the wheel position to be programmed will flash A new transmitter identification can be learned in two ways e Vigorously shake the transmitter to provoke a transmission By inflating or deflating the tire by more than 3 psi 0 2 Bar 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 A beep and rapid flashing of the alarm light indicate a transmission was received The new ID is stored 7 Press the TIRE button to scroll to another position and repeat step 4 or 5 as required 8 Press the SET button to save
75. K B 150 BK C907M 1750 BK 150 BK I Left I Rear I Blackout Do Relay 150 BK 1 S Right Rear Blackout _ 1 Relay 150 BK 1 tI 8 1704605 suigjs g DuulA pSL 9 U O Q lt jueuiejddng enuey 891449 ASST 5002 Blackout Lamp G902M Ground Distribution Schematics G902M G903M and G904M Blackout _ Lamp G903M L HG Ii Topper Dome Lamp r A BK G904M 1704986 Apog GGI g Suiejs S Bui 8 156 Wiring Systems Body Harness Routing Views Forward Blackout B O Lamp Harness 1693354 Legend 1 Instrument Panel I P Wiring Harness 4 C102M 2 Forward Lamp Harness 5 C101M 3 G100M 6 C100M 2005 LSSV Service Manual Supplement Body Wiring Systems 8 157 Harness Routing Views Rear Lamp Extension Harness LSSV d 7 fa N S LALA LOT d 1 rim t ENEH 1693353 Legend 1 C908M 3 I P Wiring Harness 2 Auxiliary Rear Lamp Wiring Harness 2005 LSSV Service Manual Supplement 8 158 Wiring Systems Body Harness Routing Views Relay Block Harness 1704988 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 2005 LSSV Service Manual Supplement Body Wiring Systems 8 159 Harness Routing Views Rear Lamp Harness 17
76. Lamp Bulb Replacement Maintenance Body License Plate Lamp Bulb Replacement Ambulance Body Removal Procedure 1 Ensure the headlamp switch is in the OFF position 2 Remove the lens assembly by pull it free of the rubber housing 3 Remove the bulb from the bulb socket Installation Procedure 1 Install the bulb into the bulb socket Important Ensure that the housing seal is fully around the lens 2 Push the lens into the rubber housing until fully seated 2005 LSSV Service Manual Supplement Lighting Systems 8 137 1692757 1692752 1692752 8 138 Lighting Systems Body License Plate Lamp Bulb Replacement Maintenance Body Removal Procedure 1 Ensure the headlamp switch is in the OFF position 2 Remove the lens assembly by pull it free of the rubber housing 3 Remove the bulb from the bulb socket 1692755 Installation Procedure 1 Install the bulb into the bulb socket Important Ensure that the housing seal is fully around the lens 2 Push the lens into the rubber housing until fully seated 1692755 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 4 Remove the bulb 1 from the voltmeter socket 1693477 2005
77. O Table RPO Description The production process codes provide the description of the LSSV Option Troop Seats with Canvas Top Optima Battery LSSV only Enhance Mobility Package Green Flat Paint LSSV only Tan Flat Paint LSSV only Pickup Cap with Bumper Mounted owing Away Spare Tire Carrier ena Opi 2005 LSSV Service Manual Supplement General Information LSSV Eguipment Options 2005 Light Service Support Vehicle LSSV Specifications Options Your vehicle may be eguipped with any combination of the following options LSSV Equipment Options Blackout B O Lighting D Rings and Receiver Hitch Tire Pressure Monitoring System Beadlock Tires Interior Air Cleaner Restrictor Gage AGM Absorbed Glass Mat Battery Optima 2005 LSSV Service Manual Supplement General Information 0 5 LSSV Labels Your vehicle may have some or all of the following labels Vehicle Load Disconnect Switch Caution Label 12 VOLT 24 VOLT VEHICLE LOAD DISCONNECT SWITCH MAIN BATTERY FEEDS TO STARTER ow WINCH amp NATO JUMP START CONNECTOR REMAIN POWERED This switch disconnects 12 volt vehicle loads amp 24 volt trailer aux loads that could cause parasitic drain on batteries Z 5 1704108 If the vehicle is equipped with a load disconnect switch the switch disconnects 12V vehicle loads and 24V trailer aux loads that could cause a parasitic drain on the batteries The switch shoul
78. Owner Checks and Services 0 8 Specifications e que ii 0 7 Periodic Maintenance Inspection DE 0 8 Capacities Approximate Fluid 0 7 2005 LSSV Service Manual Supplement 0 2 Table of Contents General Information BLANK 2005 LSSV Service Manual Supplement General Information General Information 0 3 General Information Introduction Cargo Troop Carrier Base Vehicle Identification The 2005 LSSV series pickup models derive from standard commercial vehicles The pickup is a 2500HD or 9200 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 These limits are met without causing permanent damage or requiring immediate maintenance The pickup vehicles are equipped with heavy duty shocks front and rear 4 wheel anti lock brakes a locking differential on off road tires front and rear D rings and blackout B O lighting A slave receptacle is mounted on the front of the vehicles protected by a radiator brush guard Pickup Vehicle Information 1703388 The pickup vehicles are equipped with a 6 6L Turbo Cargo Carrier Crew Cab diesel engine with a 5 speed Allison automatic transmission and 2 speed transfer case Payload Capacity is not to exceed the gross axle weight rating of the front and re
79. Repair nstructions 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 1700807 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 Tighten Tighten receiver bolts to 88 98 N m 65 72 lb ft 3 Install the center front bumper Refer to Center Front Bumper Replacement in Bumpers 1700807 2005 LSSV Service Manual Supplement 8 50 Frame and Underbody Body Front D Ring Replacement Ambulance Maintenance Body Removal Procedure 1 Remove the bolt 1 and nut 3 2 Remove the D ring 2 from the mount 1700612 Installation Procedure 1 Install the D ring 2 to the mount Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolt 1 and nut 3 Tighten Tighten nut and bolt to 200 N m 148 Ib ft 1700612 Front D Ring Replacement LSSV Removal Procedure 1 Remove the nut and bolt 2 2 Remove the D ring from the mount 3 Discard the wave washer 1 1700801 2005 LSSV Service Manual Supplement Body 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 bra
80. Replacement Removal Procedure 1 Remove the blackout B O headlamp Refer to Headlamp Replacement Blackout B O LSSV or Headlamp Replacement Blackout B O Ambulance Maintenance Body in Lighting Systems Remove the slave receptacle Refer to Slave Receptacle Replacement LSSV or Slave Receptacle Replacement Ambulance Maintenance Body in Engine Electrical Remove the bolts 1 retaining the center brush guard to the bumper Remove the center brush guard from the vehicle Installation Procedure j Notice Refer to Fastener Notice in Cautions and Notices 2 Install the center brush guard to the vehicle Install the bolts 1 retaining the brush guard to the vehicle Tighten Tighten the bolts to 20 N m 15 Ib ft Install the slave receptacle Refer to Slave Receptacle Replacement LSSV or Slave Receptacle Replacement Ambulance Maintenance Body in Engine Electrical Install the blackout B O headlamp Refer to Headlamp Replacement Blackout B O LSSV or Headlamp Replacement Blackout B O Ambulance Maintenance Body in Lighting Systems 2005 LSSV Service Manual Supplement Body Bumpers 8 29 Outer Radiator Grille Brush Guard Replacement Removal Procedure 1 Remove the center brush guard Refer to Center Radiator Grille Brush Guard Replacement 2 Remove the bolts 1 retaining the brush guard end to the bumper 3 Remove the brush guard end from the vehicle by li
81. SERVICE MANUAL Light Service Support Vehicle LSSV Enhanced Mobility Package EMP Includes General Information Military Components VOLUME 1 OF 1 LSSVSMOS5 Preface Cautions and Notices Battery DisconnectCautlon 2005 LSSV Service Manual Supplement Table of Contents P 1 Cautions and Notices VehicleliftingCaution P 3 Fastener NOTICO esuhes simsi orani sesimizi y z PR dis P 3 P 2 Table of Contents Preface BLANK 2005 LSSV Service Manual Supplement Preface Cautions and Notices Battery Disconnect Caution Caution Before servicing any electrical component the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF unless instructed otherwise in these procedures If a tool or equipment could easily come in contact with a live exposed electrical terminal also disconnect the negative battery cable Failure to follow these precautions may cause personal injury and or damage to the vehicle or its components Vehicle Lifting Caution Caution To avoid any vehicle damage serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist support the vehicle with jack stands at the opposite end from which the components are being removed 2005 LSSV Service Manual Supplement Cautions and Notices P 3 Fastener Notice Notice Use the
82. SV 6 44 Slave Receptacle Replacement LSSV 6 46 Slave Receptacle Replacement Ambulance Maintenance Body 6 47 Description and Operation 6 49 Battery Description and Operation 12V and 2AY m nemine land hai lila 6 49 Charging System Description and Operation DE 6 49 Special Tools and Equipment 6 50 Engine Controls 6 6L LLY 6 51 Specifications 6 51 Enhanced Mobility Package Engine Control Module ECM Calibrations 6 51 Repair Instructions 6 51 Engine Control Module ECM Replacement 6 51 Description and Operation 6 51 Engine Control Module ECM Bie Wet 6 51 6 2 Table of Contents Engine BLANK 2005 LSSV Service Manual Supplement Engine Engine Cooling 6 3 Engine Cooling Specifications Fastener Tightening Specifications Specification Application Metric Engine Block Coolant Drain Plug 44 lb ft Engine Coolant Heater Bolt 2 N m 18 Ib in 2005 LSSV Service Manual Supplement 6 4 Engine Cooling d SA 1701828 635657 Engine Repair Instructions Draining and Filling Cooling System Ambulance Body Tools Required e J 26568 Coolant and Battery Tester e J 38185 Hose Clamp Pliers Dra
83. Seat Bolts Troop 43 Ib f 2005 LSSV Service Manual Supplement 8 146 Seats Body Repair nstructions 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 1703173 Installation Procedure Important The left and right seat assemblies are not interchangeable Match the mounting hole pattern of the seat assembly before attempting to install 1 Unfold the third seat back from the cab down Notice Refer to Fastener Notice in Cautions and Notices 2 When properly aligned install the 2 bolts screws and nuts to the end of the rail Tighten Tighten the bolts to 58 N m 43 Ib ft 3 Install the 2 clamps bolts and nuts holding the seat assembly to the holes within the openings at the middle and forward end of the box rail Tighten Tighten the bolts to 58 N m 43 Ib ft 1703173 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
84. Step 18 Go to Step 9 Test the ground circuit of the inoperative lamp for high resistance or an open Refer to Circuit Testing and Wiring Repairs in Wiring Systems in 2005 C K Truck Service Manual Did you find and correct the condition Go to Step 18 Go to Step 12 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 O Go to Step 18 Disconnect the blackout B O marker lamp s and connect a test lamp between cavity A circuit 900 BN WH front and circuit 900 BN WH rear to ground Does the test lamp illuminate Go to Step 12 Go to Step 13 Replace blackout B O marker lamp s assembly Did you complete the replacement Go to Step 18 Locate and repair an open in circuit 900 BN WH front and circuit 900 BN WH rear wire between inline fuse and blackout B O marker lamp assembly Did you complete the repair Co Go to Step 18 Connect a test lamp between the blackout B O service switch to circuit 40 OG cavity B and ground Does the test lamp illuminate Go to Step 16 Go to Step 15 Replace the blackout B O service switch Refer to Blackout B O Switch Replacement Did you complete the replacement Go to Step 18 2005 LSSV Service Manual Supplement Body Lighting Systems 8 111 Blackout B O Marker Lamps Inoperative cont d Connect a test lamp at I P rela
85. Systems Body Introduction Blackout B O Marker Lamps Inoperative Sep Cito es NO Schematic Reference Exterior Lights Schematics and Interior Lights Schematics Did you review Blackout B O Lighting Description and Operation Go to Blackout B O 1 Lighting Circuit Go to Step 2 Operation Verify that the marker lamps are inoperative Go to Testing for Do the marker lamps operate normally Electrical Intermittents 2 in Wiring Systems in 2005 C K Truck Service Manual Go to Step 3 Are all marker lamps inoperative Go to Step 4 Go to Step 8 Inspect the fuse s check for corroded inline connectors check for broken or partially broken wires inside insulation and for properly installed aftermarket equipment Did you find the condition Go to Step 5 Go to Step 6 Make necessary repairs Did you complete the repairs Go to Step 14 1 Place blackout B O service switch in blackout B O mode 2 Connect a test lamp at cavity A circuit 911 PK wire at blackout B O service switch and ground Does the test lamp illuminate Go to Step 7 Go to Step 14 Connect a test lamp between inline fuse cavity B circuit 911 PK wire and ground Does the test lamp illuminate Go to Step 11 Go to Step 10 Test the supply circuit of the inoperative lamp for high resistance or an open Refer to Circuit Testing and Wiring Repairs in Wiring Systems in 2005 C K Truck Service Manual Did you find and correct the condition Go to
86. Tighten Tighten side bolts to 34 46 N m 25 34 Ib ft 3 Lower the vehicle Upper 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 2005 C K Truck Service Manual 2 Remove body mount bolt 1 3 Remove the upper reinforcement 2 from the radiator core support 3 Installation Procedure 1 Install the upper reinforcement 2 onto the radiator core support 3 2 Perform the following procedure before installing the bolts e 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 Notice Refer to Fastener Notice in Cautions and Notices 3 Install the body mount bolt 1 Tighten Tighten body mount bolt to 70 N m 52 Ib ft 4 Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual 2005 LSSV Service Manual Supplement Frame and Underbody 8 55 1700805 1700812 1700812 8 56 Frame and Underbody 1700810 1700810 1700619 Body Lower Radiator Support Reinforcement Removal Procedure Caution Refer to Vehicle Lifting Caution in Ca
87. a test lamp from blackout B O service switch cavity A circuit 911 PK and ground Does the test lamp illuminate Locate and repair open in circuit 911 PK between blackout B O service lamp switch and blackout B O drive relay Did you complete the repair NO Connect a test lamp from the blackout B O service switch at cavity B circuit 40 OG and ground Does the test lamp illuminate D 1 Disconnect blackout B O headlamp switch 2 Connect a self powered test lamp between blackout B O headlamp switch cavity E circuit 150 BLK and ground Does the test lamp illuminate Replace blackout B O headlamp switch Refer to Blackout B O Switch Replacement Did you complete the replacement 2005 LSSV Service Manual Supplement 8 108 Lighting Systems Body Blackout B O Headlamp Inoperative cont d Ain TTS Locate and repair open in circuit 150 BLK wire between blackout B O headlamp switch and ground Did you complete the repair Go to Step 20 Locate and repair open in circuit 40 ORN wire between connector C241 and blackout B O service lamp switch cavity B Did you complete the repair Go to Step 20 Replace blackout B O service switch Refer to Blackout B O Switch Replacement Did you complete the replacement Go to Step 20 D I Seemok cote ste Did you correct the condition System OK Go to Step 2 Blackout B O Headlamp Always On Sep Acion Uag Na Sc
88. ackout B O Ambulance Maintenance Body 2005 LSSV Service Manual Supplement Body 5 Remove the bolts 1 from the end cap brace 6 Remove the end cap from the vehicle Installation Procedure 1 Install the end cap to the vehicle Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts 1 to the end cap Tighten Tighten the bolts to 88 98 N m 65 72 Ib ft 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 Ib ft 4 Install the blackout B O marker lamp Refer to Marker Lamp Replacement Front Blackout B O LSSV or Marker Lamp Replacement Front Blackout B O Ambulance Maintenance Body 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 2005 LSSV Service Manual Supplement Bumpers 8 35 1700819 1700819 1698255 8 36 Bumpers Body Bracket Replacement Front Bumper Removal Procedure 1 Remove the center brush guard 2 Refer to Center Radiator Grille Brush Guard Replacement 2 Remove the end brush guard 1 Refer to Outer Radiator Grille Brush Guard Replacement 3 Remove the center bumper 4 Refer to Center Front Bumper Replacement 4 Remove the bumper end cap 3 Refer to Bumper End Cap Replacement Fro
89. ackup lamp switch Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems in 2005 C K Truck Service Manual Did you find and correct the condition Repair the short to voltage in the backup lamp supply voltage circuit Refer to Circuit Testing and Wiring Repairs in Wiring Systems in 2005 C K Truck Service Manual Did you complete the repair Replace the backup lamp switch Refer to Park Neutral Position Switch Replacement in Automatic Transmission Allison in 2005 C K Truck Service Manual Did you complete the replacement Go to Diagnostic System Check Vehicle in Vehicle Controls System in 2005 C K Truck Go to Step 2 Service Manual Go to Testing for Intermittent Conditions and Poor Connections in Wiring Systems in 2005 C K Truck Service Manual Go to Step 3 Go to Step 7 Go to Step 6 Go to Step 7 Go to Step 7 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 3 2005 LSSV Service Manual Supplement 8 118 Lighting Systems Body Backup Alarm Inoperative Go to Diagnostic System Check Vehicle in Vehicle Controls System in 2005 C K Truck Go to Step 2 Service Manual 1 Block the wheels and set the parking brake Go to Testing for 2 Turn ON the ignition with the engine OFF Intermittent Conditions and Poor Connections 3 Place the gear selector in and out of the reverse position in Wiring Systems i
90. all the positive battery cable bolt 2 cable to the starter connection and spacer 5 Install the positive battery bolt cable bolt 3 through the cable and into the positive battery terminal of the right rear underhood battery Tighten Tighten the bolt to 17 N m 13 Ib 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 Refer to Battery Cable Disconnect Connect Procedure 2 Remove the negative battery cable to frame bolt 8 3 Remove the negative battery cable 10 from the vehicle 2005 LSSV Service Manual Supplement Engine Installation Procedure Important Ensure that all battery terminal connections are clean 1 Clean the area around the battery cable to frame bolt 2 Install the battery cable bolt 8 through the battery cable 10 Notice Refer to Fastener Notice in Cautions and Notices 3 Install a new star washer 9 and tighten bolt into the frame Tighten Tighten the bolt to 25 N m 18 lb ft 4 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure 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
91. and Operation Go to Blackout B O Lighting Circuit Go to Step 2 Operation 1 Place the blackout B O service switch in blackout B O mode 2 Connect a test lamp at cavity C of the blackout B O switch and ground Does the test lamp illuminate Go to Step 3 Go to Step 6 1 Disconnect the blackout B O service switch connector from the switch 2 Connect a test lamp at cavity C of the connector and ground Does the test lamp illuminate Go to Step 5 Go to Step 4 Replace the blackout B O service switch Refer to Blackout B O 4 Switch Replacement Did you complete the replacement Go to Step 9 Locate and repair the short to voltage on circuit 912 OG eee Did you complete the repair Go to Step 9 Remove the park lamp interrupt relay from the relay module uem mm D yo comper me repase L oto spe Did you complete the replacement Go to Step 9 Locate and repair the short to voltage on circuit 1080 WH el Did you complete the repair Go to Step 9 Operate the system in order to verify the repair e l Did you correct the condition System OK Go to Step 2 2005 LSSV Service Manual Supplement Replace the blackout B O service switch Refer to Blackout B O 4 Switch Replacement Did you complete the replacement Go to Step 9 Body Lighting Systems 8 115 CTSY Lamps Operate in Blackout B O Mode Schematic Reference Exterior Lights Schematics and Interior L
92. and exit 2005 LSSV Service Manual Supplement Tire Pressure Monitoring 3 47 1641563 1641564 3 48 Tire Pressure Monitoring 1641558 1641560 Suspension If no error is found the system will reset and go to normal mode If more than one tire location contains the same sensor ID the display will prompt an error and flash between this message and the display with the conflicting tires filled in If so indicated repeat the programming procedure above Learn Procedure with Initiator Tools Required 090 0006 Programming Initiator Learn Mode Description Important To ensure proper operation the Programming Initiator must be held facing the sensor for at least 5 seconds after the appropriate button is pressed Sensors are normally located next to the valve Hold the initiator against the tire and point it towards the sensor from a position slightly outside the rim flange 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 The vehicle does not have to be moving to accomplish this task which allows programming of
93. 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 spare tire wheel nuts 2 Remove the spare tire from the spare tire carrier 3 Remove the short bolts 2 from both sides of the carrier 4 Remove the long bolts 1 from both sides of the Carrier 5 Remove the carrier from the bed of the vehicle 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 Ib ft 2 2 Tighten the short carrier bolts 2 to 68 N m 50 Ib ft 3 Install the spare tire onto the spare tire carrier 4 Install the wheel nuts onto the studs Tighten Tighten the spare tire nuts to 90 N m 66 lb ft Spare Tire Carrier Replacement Swing Away 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 spare tire wheel nuts 2 Remove the spare tire from the spare tire carrier 3 Unlatch and open the spare tire carrie
94. anual 2005 LSSV Service Manual Supplement Disc Brakes 5 7 794150 5 8 Disc Brakes Brakes BLANK 2005 LSSV Service Manual Supplement Table of Contents 6 1 Section 6 Engine Engine Engine Cooling 6 3 Specifications 6 3 Fastener Tightening Specifications 6 3 Repair Instructions 6 4 Draining and Filling Cooling System Ambulance Body 6 4 Coolant Heater Replacement 6 7 Special Tools and Equipment 6 9 Engine Electrical 6 10 Specifications 6 10 Fastener Tightening Specifications 6 10 Battery Usage Optima 6 10 Generator Usage 6 10 Battery Charging Specifications Optima 6 10 Schematic and Routing Diagrams 6 10 Starting and Charging Schematics 6 11 Componentlocator 6 15 Engine Electrical Component Views 6 15 Engine Electrical Connector End Views 6 21 Diagnostic Information and Procedures 6 22 Diagnostic Starting Point Engine zwei e 6 22 Symptoms Engine Electrical
95. any dirt or foreign materials Clean the beadlock edges with a clean towel and remove any foreign materials e Wipe the O ring groove with a clean towel and remove any foreign material from the groove Clean the mating surfaces on the outer and inner wheel halis 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 Important The sensor must be opposite one of the two beadlock grooves 2 3 Install the tire pressure sensor assemble 1 within the beadlock groove 2 2005 LSSV Service Manual Supplement Tires and Wheels 3 19 1697948 1697949 3 20 Tires and Wheels 1697951 1697938 1697939 Suspension Position the beadlock centering it between the tire beads Lubricate the inner edge of the beadlock wheel and tire beads with tire soap to aid installation of the wheel Center the wheel air fitting with one of the grooves in the beadlock and press inner wheel into tire Install the air valve into the rim pulling into position On the outer wheel apply a small amount of run flat lubricant D528235 H1 to the O ring gro
96. ar axle The pickup has a cargo cover and troop seating for up to eight or a hard cap with opening windows A specially upgraded electrical system can handle 24V communications equipment and charging of the 24V battery Cargo Carrier Base 1703389 1703386 2005 LSSV Service Manual Supplement 0 4 General Information Cargo Troop Carrier Crew Cab General Information Maintenance Body Information 1703391 Ambulance Body Information 1703367 The ambulance vehicle is eguipped with a 6 6L Turbo diesel engine with a 5 speed Allison automatic transmission and 2 speed transfer case The vehicle is not designed for towing a trailer Payload capacity is not to exceed the gross axle weight rating of the front and rear axle For ambulance body parts and maintenance refer to the ambulance Parts and Maintenance manual 1703368 The maintenance vehicle is equipped with a 6 6L Turbo diesel engine with a 5 speed Allison automatic transmission and 2 speed transfer case Payload Capacity is not to exceed the gross axle weight rating of the front and rear axle The maintenance body has multiple compartments and a large open cargo space There are adjustable shelves and material trays that organize the storage units The storage doors are keyed alike and are double panel steel and incorporate weather tight seals The endgate of the body can be folded down for easy loading and unloading of cargo RPO Code List RP
97. 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 Connect the slave cable to the vehicle with the good battery Important It may take up to 30 minutes to charge the battery enough to start the vehicle depending on its state of charge 7 Allow the vehicle with the dead battery to charge for 10 minutes 8 Start the vehicle with the dead battery Important Never remove the cables with the starter engaged 9 Remove the slave cable in the reverse order that it was installed Take care not to let the cables touch a metal surface 10 Reinstall the slave start covers 2005 LSSV Service Manual Supplement Engine Engine Electrical 6 25 24V Generator Noise Diagnosis Diagnostic Aids generators When diagnosing a noisy generator it is i r misalign Noise from a generator may be due to electrical or le bl ll rle me mechanical noise Electrical noise or magnetic whine S e u g y usually varies with the electrical load placed on the noise into the passenger compartment and that generator and is a normal operating characteristic of all replacing the generator may not solve the problem 24V Generator Noise Diagnosis Yes Test the generator for proper operation using the generator tester Refer to Charging System Testin E
98. assists the technician in programming newly installed sensors and in verifying the correct installation of these sensors Initiator Functions This function is used after the sensors are installed to confirm whether the sensor positions were properly programmed in the receiver Pressing this button while holding the initiator against the tire sidewall adjacent to the sensor causes the sensor to transmit its ID tire pressure and temperature data Initiate This function should only be used when the sensors are taken out of the tire and need De energize to be shipped back to the supplier Pressing this button while holding initiator next to the side of the sensor causes it to stop transmitting This function is used to provoke a Learn transmission from the sensor in order to Learn program the receiver Pressing this button while holding the initiator against the tire sidewall adjacent to the sensor causes it to transmit its Learn signal LED Functions E Femen OS SmarTire Initiator is working properly omarTire Initiator is not working properly Contact SmarTire regarding repair or replacement Battery is low Powering On the SmarTire Initiator The amount of deviation from the required pressure The SmarTire Initiator is powered with a 9 volt battery E a bag kA pan E K d the f that is installed by opening the battery access panel ressure Deviation mode of this SmarTire product on the back An ON OFF switch is located on the righ
99. at 41 amperes 6 50 Engine Electrical Engine 24V Voltmeter Gage Special Tools and Equipment A voltmeter is installed to monitor the status of the illustration Tool Number Description 24V battery and the 24V generator Om nen Voltage is available through a circuit of the 24V 10A 7 fuse When the vehicle load disconnect switch is placed in the ON position voltage is applied to the 24V fuse that provides voltage to the voltmeter The voltmeter is grounded through the I P relay block J 42000 Color graduations as viewed from the front of Battery Tester the meter from left to right are as follows Minimum voltage to activate the pointer Red Yellow Break Point 22 0 volts Yellow Green Break Point 26 0 volts Small Hack Mark in green 18 0 volts 28 5 volts 1704705 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 2005 LSSV Service Manual Supplement Engine Engine Controls 6 6L LLY 6 51 Engine Controls 6 6L LLY Specifications Enhanced Mobility Package Engine Control Module ECM Calibrations Calibration PIN LT285 75R16 628 Rev Mile 392 Rev per Kilometer 15130245 LT285 75R16 628 Rev Mile 392 Rev per Kilometer 15130246 LT285 75R16 628 Rev Mile 392 Rev per Kilometer
100. atir sans ms sile Dres Dudes aas 1 3 Fastener Tightening Specifications 1 3 Refrigerant System Capacities 1 3 2005 LSSV Service Manual Supplement Repair Instructions 1 4 Heater Water Valve Replacement Ambulance Body eseri mi day al 1 4 Coolant Booster Pump Replacement Ambulance Bodyless esse to ee ett 1 5 Description and Operation 1 6 Ambulance Heating System 1 6 1 2 Table of Contents HVAC BLANK 2005 LSSV Service Manual Supplement HVAC Heating Ventilation and Air Conditioning 1 3 Heating Ventilation and Air Conditioning Specifications Fastener Tightening Specifications Specification Application English Booster Pump Shield Bolts 80 Ib in Water Shut Off Valve Bolts 80 Ib in Refrigerant System Capacities Important These capacities apply only to the ambulance body vehicles For pickup and maintenance body vehicles refer to the 2005 C K Truck Service Manual Refrigerant System Capacities Ambulance Body Lo mien 0000 eee PAG Oil GM P N 12378526 for United States R 134a Total System Refrigerant Charge 3 0 kg 66b Total System PAG Oil Capacity with Rear A C 328 ml 2005 LSSV Service Manual Supplement 1 4 Heating Ventilation and Air Conditioning HVAC Repair nstructions 1702776 6 1702776 Heater Water Valve Replacement Ambulanc
101. attery 24V Schematic Frame i in Wiring System Mount 12V Battery Left 24V 32 RD Generator 12V Right Solid State nega Winch Prep l2 Wiring Vehicle 1 Schematics Load pee 3 Disconnect Charging Starting Diesel _ Switch schematic i Schematic in Y 4 P 2N a Engine Electrical 2005 C K Truck 900 Service Manual RD 3 Power Distribution i Schematics in Wiring Systems G103M 1702790 29147993 euiDu3 Z L 9 ouiDu3 jueuiejddng enuey 891449 ASST 5002 Starting and Charging Schematics Charging Schematics 24V Lo 900 RD 0 8 32 RD e D C Es Vehicle Battery Slave S Load Left Battery Start Disconnect 24V Schematic Receptacle Switch tJunction 8009 RD BK 2 0 8009 RD BK 2 0 1 Block Vehicle i Underhood Load 8009 8009 S104M A TRY Disconnect RD BK RD BK 24V Switch 2 0 8 0 Accessory 1 25A Fusible 0 8 ED Trailer Link B Fuse 13 25A 8009 RD GRY Accessory Power B 8009 8014 YE 0 8 2 0 24V Connector e L L 802 Underhood cadet tinn A Power Distribution m ASL Fuse t Schematicsin i di 1 Generator i Block d de zem E 4 Rectifier 24V Right i i Underhood Bridge Solid State rl Regulator 30 86 1 5K OHM 8008 BN 8008 9 8 BN 0 8 8008 BN A B E E A 0 8 8008 BN 0 8 l 8004 S105M FC mi e e iy e 1 Accessory RD i A i Panel ac Block 8 0 en 24V Voltmeter i A L P use Block Gage Fuse i nn i i
102. attery Disconnect Caution in Cautions and Notices 3 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Caution Refer to Vehicle Lifting Caution in Cautions and Notices 4 Raise the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual Important Label all wires and their location for reassembly 5 Remove the shield both covers and wires from the distribution panels 1 6 Remove the wiring harness clamps 2 and lay the harness aside 7 Disconnect the wiring harness for the taillamps 1 Refer to Taillamp Replacement Maintenance Body in Lighting Systems 8 Disconnect the wiring harness for the backup lamps 3 Refer to Backup Lamp Replacement Ambulance Body in Lighting Systems 9 Disconnect the wiring harness for the license plate lamp 2 Refer to License Plate Lamp Replacement LSSV or License Plate Lamp Replacement Maintenance Body or License Plate Lamp Replacement Ambulance Body in Lighting Systems 10 Remove wiring going to the body marker lamps and backup alarm 2005 LSSV Service Manual Supplement Body Body Rear End 8 17 11 Loosen the tube nuts 2 from the A C line tubes 12 Disconnect the tubes from the A C lines 13 Remove and discard the O rings 14 Remove the bolt 1 and clamp securing the lines to the vehicle 15 Plug the open A C lines 1701827 16 Loosen t
103. blackout B O switch and ground Does the test lamp illuminate Go to Step 3 Go to Step 6 1 Disconnect the blackout B O service switch connector from the switch 2 Connect a test lamp at cavity C of the connector and ground Does the test lamp illuminate Go to Step 5 Go to Step 4 Replace the blackout B O service switch Refer to Blackout B O 4 Switch Replacement Did you complete the replacement Go to Step 9 Locate and repair the short to voltage on circuit 912 OG eee Did you complete the repair Go to Step 9 Remove the turn signal interrupt relay mem mm reaa vpn sea Did you complete the replacement Go to Step 9 Locate and repair the short to voltage on circuit 639 PK el Did you complete the repair Go to Step 9 Operate the system in order to verify the repair Lm Did you correct the condition System OK Go to Step 2 2005 LSSV Service Manual Supplement Replace the blackout B O service switch Refer to Blackout B O 4 Switch Replacement Did you complete the replacement Go to Step 9 8 116 Lighting Systems Body Hi Beam Headlamps Operate in Blackout B O Mode Schematic Reference Exterior Lights Schematics and Interior Lights Schematics Did you review Blackout B O Lighting Description and Operation Go to Blackout B O Lighting Circuit Go to Step 2 Operation 1 Place the blackout B O service switch in blackout B O mode 2 Connect a test
104. bolts Tighten Tighten hitch bolts to 90 N m 66 Ib ft 3 Install the winch connector Refer to Rear Winch Harness and Connector Replacement LSSV or Rear Winch Harness and Connector Replacement Maintenance Body in Engine Electrical 1700803 2005 LSSV Service Manual Supplement Body Horns 8 63 Horns Schematic and Routing Diagrams 2005 LSSV Service Manual Supplement jueuiejddng jenuey 891449S ASST 5002 Horn Schematics Fuse Block Underhood i i C4 WAG 1329 D GN 0 8 1329 D GN 1329 C160M D GN 0 5 B Horn Horn Left Right Ground Distribution 100 Schematics in Wiring Systems Me mo e i e e e 4 qnm mh e ek dein ek iii ili ie mm I pg Blackout Lights Service ON Switch I Aj Blackout i OFF ON i S107M C107M I i Horn Relay Ba i Blackout Lighting 106M Relay oe Center 150 BK 0 8 Ground Distribution Schematics in Wiring Systems G105M SUIOH p9 8 U O Q lt Body Horns 8 65 Diagnostic Information and Procedures Symptoms Horns Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom e Horns Inoperative in Blackout B O Mode e Horns Operate In Blackout B O Mode Horns Inoperative in Blackout B O Mode Step ction es NO Schematic Reference Horn Schematics Did you review Horns Description and Operation
105. c Brakes 5 3 Disc Brakes Specifications Fastener Tightening Specifications Specification Application Brake Caliper Bolt 80 Ib ft Brake Caliper Bracket Bolt 221 Ib ft Brake Caliper Nut 33 Ib ft 2005 LSSV Service Manual Supplement 5 4 Disc Brakes 1703384 1703384 Brakes 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 2005 C K Truck Service Manual 2 Remove the cover nuts 8 3 Remove the caliper cover 2 4 If damaged remove the caliper bolts 1 Refer to Rear Brake Caliper Bolt Replacement Installation Procedure 1 If removed install the caliper slide pins 1 Refer to Rear Brake Caliper Bolt Replacement 2 Install the caliper cover 2 Notice Refer to Fastener Notice Fastener Notice in Cautions and Notices 3 Install the cover nuts 3 Tighten Tighten cover nuts to 45 N m 33 Ib ft 4 Remove supports and lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in the 2005 C K Truck Service Manual 2005 LSSV Service Manual Supplement Brakes Disc Brakes 5 5 Rear Brake Caliper Bolt Replacement Removal Procedure Caution Refer to Brake Dust Caution in Cautions and Notices in 2005 C K Truck Service Manual 1 Inspect the fluid leve
106. cedure 1 Install the alarm to the vehicle Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts 1 retaining the alarm to the body Tighten Tighten the alarm bolts to 0 8 N m 7 Ib in 3 Install the wiring connectors and nuts 2 Tighten Tighten the wiring harness nuts to 0 8 N m 7 Ib in 4 Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information 2005 LSSV Service Manual Supplement Lighting Systems 8 121 BLACKOUT DRIVE LIGH7 BLACKOUT Z E lt AN d U D a BEEN UN mma Ij Mf M L L LID A PC LF fT LANA e a A LZ RE l Z E Ew MN ON c CUL Na aN T Mf LL M l L LAN O CI L ee NA WEE Cem e L Nl LZ O A at dl Dd L 1693358 1706970 1706970 8 122 Lighting Systems Body 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 table turn the trailer connector 1 and pull out from the bumper 1707001 Installation Procedure 1 Install the trailer connector 1 into the opening in bumper 2 Turn the connector until lock tabs engage 3 Connect the harness connector into the trailer lamp connector 1707001 Commercial Trailer Connector Replacement Maintenance Body Removal Procedure 1 Ensur
107. cement Rear LSSV in Bumpers 2005 LSSV Service Manual Supplement Frame and Underbody 8 53 1700786 1700804 1700804 8 54 Frame and Underbody 1700813 1700813 1700805 Body Rear D Ring Bracket Replacement LSSV Removal Procedure 1 Remove the D ring Refer to Rear D Ring Replacement Maintenance Body or Rear D Ring Replacement LSS V 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 bracket mounting bolts 1 Tighten Tighten the bolts to 97 N m 72 Ib ft 3 Install the D ring Refer to Rear D Ring Replacement Maintenance Body or Rear D Ring Replacement LSS V D Ring Bracket Crossmember Replacement Maintenance Body 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 2005 C K Truck Service Manual 2 Remove the bolts 1 from both sides of the crossmember 3 Remove the crossmember from the vehicle 2005 LSSV Service Manual Supplement Body Installation Procedure 1 Install the crossmember on the vehicle and line up mounting holes Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts 1 on both sides of the crossmember
108. ces 1 2 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure Trace the negative slave receptacle cable connector 1 to the cable ground connection Disconnect the negative slave receptacle ground cable from the ground connection Trace the positive slave receptacle cable connector 3 to the 24V battery connection Disconnect the positive slave receptacle cable 3 from the 24V battery connection Disconnect the slave receptacle connectors from the slave receptacle Refer to Slave Receptacle Replacement LSSV or Slave Receptacle Replacement Ambulance Maintenance Body Remove the fasteners from the clamps securing the slave receptacle harness and the blackout B O harness Remove the slave receptacle harness from the bumper assembly 2005 LSSV Service Manual Supplement Engine Electrical 6 43 1707377 1706661 1700940 6 44 Engine Electrical 1700940 1706661 1706972 2 Engine Installation Procedure Important Verify all connections are clean prior to installation 1 Position the slave receptacle harness onto the bumper assembly Install the 3 clamps and the fasteners onto the slave receptacle harness and the blackout B O harness Connect the slave receptacle connectors to the slave receptacle Refer to Slave Receptacle Replacement LSSV or Slave Receptacle Replacement Ambulance Maintenance Body
109. cket 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 Maintenance Body Removal Procedure 1 Remove the bolt 1 and nut 2 2 Remove the D ring 3 from the bracket Installation Procedure 1 Install the D ring 3 onto the bracket Notice Refer to Fastener Notice in Cautions and Notices Important D rings must move once torqued Do not over torque 2 Install the bolt 1 and nut 2 Tighten Tighten nut and bolt to 200 N m 148 lb ft 2005 LSSV Service Manual Supplement Frame and Underbody 8 51 1700801 1700806 1700806 8 52 Frame and Underbody 1700816 1700816 1700786 Body 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 Installation Procedure Important The flat side of the D ring must be facing out 1 Install the D ring on the bracket Notice Refer to Fastener Notice in Cautions and Notices 2 Slide the new wave washer 2 between the D ring and the bracket 3 Install the D ring nut and bolt 1 Tighten the nut and bolt until the D ring will stand straight out on its own Front D Ring Bracket Replacement Removal Procedure 1 Remove the D ring Refer to Front D Ring Replacement Ambulance Maintenance Body or Front D Ring Replacement LSSV 2 Remove the D
110. coolant heater bolt Remove the engine coolant heater from the engine block Do not score the machined surface of the hole Grasp the plug with pliers Pull the plug from the engine block Clean the core plug hole in order to remove the following substances Burrs e Compound e Paint e Rough spots O OO OO N Installation Procedure 1 Coat the O ring seal and the cleaned surface of the plug opening with water resistant high temperature grease lubricant GM P N 1052196 Canadian P N 5264008 or the equivalent Important Avoid element contact with the inside walls of the engine block 2 Align the coolant heater element to point towards the top of the engine 3 Tightly push the coolant heater into the engine block 2005 LSSV Service Manual Supplement Engine Cooling 6 7 Sy LN RX de fd RAS a FS br D N S vw 4 26 44 S UE 674570 663089 663089 6 3 Engine Cooling Engine Notice Refer to Fastener Notice in Cautions and Notices 4 Tighten the bolt on the engine coolant heater until both of the locking wings draw tightly against the inner wall of the engine block Tighten Tighten the bolt to 2 N m 18 lb in 312945 Notice The heater cord must not touch the engine hot pipes manifold or any moving parts Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage S le Rw AN N 5
111. 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 These coatings affect fastener torque and joint clamping force and may damage the fastener Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems P 4 Cautions and Notices Preface BLANK 2005 LSSV Service Manual Supplement General Information Table of Contents 0 1 Section 0 General Information General Information 0 3 Fluid and Lubricant Recommendations 0 7 Introduction EE NEM ERE AM 0 3 Tire Inflation Pressure Specifications 0 7 Vehicle Identification 0 3 Tire Pressure Monitoring System RPO Code List sssseees 0 4 Settings EMP Only 0 8 LSSV Equipment Options 0 5 Maintenance Items eee 0 8 LSSV Labels 0 5 Maintenance 0 8 l mM Maintenance Schedule 0 8 Maintenance and Lubrication Et
112. croll to the desired axle The tires of the selected axle are filled in Press the MODE button to enter and display the current value Press the TIRE button to increase the value Press the MODE button to decrease the value Press the MODE button until the display shows OFF to disable this feature Press the SET button to save when the desired value is reached Press the SET button again to revert to normal view 2005 LSSV Service Manual Supplement Tire Pressure Monitoring 3 43 1641549 1641550 1641551 3 44 Tire Pressure Monitoring Suspension 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 Press the MODE button to decrease the value 1641552 6 To disable this feature press the MODE button until the display reads OFF 7 Press the SET button to save and exit this mode when the desired value is reached 8 Press the SET button again to revert to normal mode 1641554 Metric or Imperial Measurement Selection Important Use this mode to select the combination of pressure a
113. cur repeat step 7 Important Waiting too long to select the next tire position or existing the LEARN mode increases the likelihood of inadvertently overwriting the recently learned sensor by receiving signals from other sensors installed on the vehicle or from other vehicles in close proximity 8 If programming more sensors into the system immediately select the next tire position on the gage display and repeat step 8 until all sensor ID numbers and their appropriate positions have been learned by the receiver 2005 LSSV Service Manual Supplement Tire Pressure Monitoring 3 49 1641563 1693467 3 50 Tire Pressure Monitoring Suspension Important If an ERR message is displayed together with flashing tire positions those indicated positions have been programmed with the same sensor ID numbers In this case press the TIRE button on the system switch panel to re enter the receiver LEARN mode and reprogram the sensor positions that were flashing 9 Immediately exit the receiver LEARN mode by pressing the SET button on the system switch panel Verifying Correct Sensor Position 1 Turn ON the ignition with the engine OFF 2 Apply the parking brake 3 Place the initiator next to each sensor position but this time press the INITIATE button to cause each sensor to transmit ID number and tire data to drive the vehicle above 6 mph 4 If the correct tire sensor positions are not being received Refer to L
114. d Owners Manual Supplement Refer to the Maintenance Schedule subsection of the Owners Manual Owner Checks and Services If the engine controls instruments or gages do not operate as described in this supplement manual refer to one of the following manuals e 2005 C K Truck Owners Manual e 2005 C K Truck Service Manual e 2005 Diesel Engine Owners Manual Supplement e 2005 LSSV Owners Manual Supplement If the concern still has not been corrected shut down the engine and notify your maintenance unit or dealership 0 34 Bar 13 PSI 0 90 Bar Periodic Maintenance Inspection Inspect the condition of the headlamps taillamps turn signals side lamps and blackout B O lamps before beginning to operate the vehicle each time Inspect the axle vent tube filter for blockages every six months and more often when difficult off road conditions are encountered Replace as needed Refer to Front Axle Vent Tube Filter Replacement in Front Drive Axle or Rear Axle Vent Tube Filter Replacement in Rear Drive Axle Inspect the transfer case vent tube filter for blockages every six months and more often when difficult off road conditions are encountered Replace as needed Refer to Transfer Case Vent Tube Filter Replacement in Transfer Case NVG 261 NP2 2005 LSSV Service Manual Supplement HVAC Table of Contents 1 1 Section 1 HVAC Heating Ventilation and Air Conditioning 1 3 Specifications s
115. d be placed in the OFF position when the vehicle is parked for an extended period of time The load disconnect switch is located on the underhood fuse block The underhood fuse block is located on the driver s side of the vehicle to the rear of the battery or under the accessory panel of the ambulance body 0 6 General Information General Information 24V Battery Caution Label 12 VOLTS 24 VOLTS CAUTION BATTERY 24 VOLTS DO NOT GROUND TERMINALS PART NO TXO16079 1704110 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 O U S PROPERTY NOMENCLATURE TRUCK LSSV MCTL MAKE AND MODEL CHEV2500HDCK25903 MFRS VIN 1GCHK24133E321226 REGISTRATION NO N A CURB WEIGHT MAX PAYLOAD GVWR GCWR 6860 LBS 2340 LBS 9200 LBS 22000 LBS DATE OF DELIVERY 10 08 03 WARRANTY 36 MONTHS 36 000 MILES CONTRACT NO GS 3QF K0002 RPNNL5086 PART NO TX181623 1704112 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 Shipping Data Plate K25903HD SHIPPING DATA PLATE 2071 0 330 2 r L l 7 at 1935 0 n ea wu 1693 0 1104 5 3378 0 rore T 2892 478 VOLUME iH X WXL 23 4n 1704113 The shipping data pla
116. e 2005 LSSV Service Manual Supplement Engine Electrical 6 49 Battery Storage Because of Optima s high purity lead grid it has a self discharge rate much lower than conventional flat plate batteries This means the Optima can sit for longer periods retaining enough charge to start your vehicle The vehicle load disconnect switch must be in the OFF position anytime the expected vehicle storage time is to exceed 10 days When possible store your battery in a cool dry location Check the battery voltage every 6 months and charge if it falls below 12 6 volts If the vehicle is to be stored for long periods you should use a maintenance charger to compensate for this drain This charger should be voltage regulated between 13 2 13 8 volts 1 amp maximum Charging System Description and Operation Charging The Light Service Support Vehicle LSSV vehicles are equipped with a 24V generator The 24V generator s electronics are isolated from the chassis ground The 24V configuration provides sufficient capacity and reserve for 24V loads Electrical loads can be connected indefinitely while the engine is running and for a limited time when engine is OFF The 24V battery must be above 7 volts in order for the generator to turn ON The generator features permanently lubricated bearings Service should only include the tightening of mounting components Otherwise the generator is replaced as a complete unit The generator is rated
117. e 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 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 2005 LSSV Service Manual Supplement Front Drive Axle 4 3 1701843 1701843 4 4 Rear Drive Axle Rear Drive Axle 1701841 1701841 Driveline 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 2005 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 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 1 to the h
118. e Body Removal Procedure 1 Drain the engine coolant Refer to Draining and Filling Cooling System Ambulance Body in Engine Cooling Caution Refer to Vehicle Lifting Caution in Cautions and Notices Raise the vehicle Refer to Lifting and Jacking the Vehicle in General Information in the 2005 C K Truck Service Manual Loosen the hose clamps 2 from the heater water shut off valve inlet and outlet Remove the inlet and outlet hose from the heater water valve Disconnect the heater water shut off valve wiring Remove the heater water shut off valve retaining bolts 1 Remove the heater water shut off valve Installation Procedure 1 Notice Refer to Fastener Notice in Cautions and Notices 2 Install the heater water shut off valve Install the heater water shut off valve retaining bolts 1 Tighten Tighten the bolts to 9 N m 80 Ib in Connect the heater water shut off valve wiring Reposition and tighten the hose clamps 2 on the heater water shut off valve inlet and outlet Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in the 2005 C K Truck Service Manual Fill the engine coolant Refer to Draining and Filling Cooling System Ambulance Body in Engine Cooling 2005 LSSV Service Manual Supplement HVAC Heating Ventilation and Air Conditioning 1 5 Coolant Booster Pump Replacement Ambulance Body Removal Procedure
119. e Tire Carrier Replacement Swing Away 3 23 Spare Tire Carrier Pivot Bracket Replacement Swing Away 3 25 2005 LSSV Service Manual Supplement Spare Tire Carrier Latch Replacement Swing Away 3 26 Spare Tire Carrier Latch Adjustment Swing Away 3 28 Spare Tire Replacement In Vehicle 3 29 Description and Operation 3 30 General Description ssss 3 30 Tires Description 3 30 Special Tools and Equipment 3 30 Tire Pressure Monitoring 3 31 Schematic and Routing Diagrams 3 31 Tire Pressure Monitoring System DO MEI Al E AYA 3 32 ComponentlLocator 3 33 Tire Pressure Monitoring System Component Views 3 33 Tire Pressure Monitoring System Connector End Views 3 36 Diagnostic Information and Procedures 3 36 EE qe act agai a mr a e er 3 36 Re 3 36 CHES orena il 3 37 EA TT 3 37 Repair Instructions 3 38 Tire Pressure Monitoring Receiver Replacement EE 3 38 Tire Pressure Monitoring Gage arie nee e e eee 3 39 Tire Pressure Monitoring Switch Panel Replacement esri
120. e light blackout B O switch remains in the ON or down position Pulling the left blackout B O drive light switch out and down to the OFF position will turn it OFF Releasing the switch from ON or OFF will cause it to return to the center position automatically The following Exterior Interior lights function tables are for the service light blackout B O control switch and clarify under what conditions various exterior and interior lighting functions activate Additional details are found in the 2005 C K Truck Owner Manual Topper Dome Lamp Circuit Description When the ignition switch is ON voltage is supplied from the blackout B O switch to the interior toggle switch on circuit 912 OG The voltage leaves the switch on circuit 800 BR or 803 BN WH depending on the switches position The voltage on these circuits goes to the rear toggle switch then to the topper dome lamp The lamp is ground on the CHMSL circuit Topper Dome Lamp Description The topper dome lamp is controlled by two 3 way switches and a lamp mounted switch The interior switch is mounted in the accessory panel and the other is mounted on the left rear of the pickup bed The switch mounted on the lamp must be in the ON position for the two 3 way switches to operate the lamp Voltmeter Lamp Circuit Description When the headlamp switch is in the ON position voltage is applied through the BN 9 wire and is grounded through the BK 150 wire Voltmeter Lam
121. e that all lamp switches are in the OFF position 2 Disconnect the harness connector 4 from the trailer connectors 1 1706657 2005 LSSV Service Manual Supplement Body 3 Release the lock table 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 Connect the harness connector 4 into the trailer lamp connector 1 2005 LSSV Service Manual Supplement Lighting Systems 8 123 1706658 1706658 zm TIT S ames ve L a i fey Pager ay ed RE 1706657 8 124 Lighting Systems Body Military Trailer Connector Replacement LSSV Removal Procedure 1 Ensure that all lamp switches are in the OFF position 2 Disconnect the trailer harness connectors 1 3 Remove the fasteners securing the connector to the bumper 4 Remove the cover 3 and trailer connector 2 1707000 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 Ib in 3 Connect the harness connectors 1 1707000 Military Trailer C
122. e the tire to air pressure and inspect for leaks by placing the wheel in a water tank or letting it sit for 48 hours If the pressure loss is less than 1 psi 7 kPa the tire is acceptable for use 2005 LSSV Service Manual Supplement Tires and Wheels 3 21 Lll S e 1697941 1697942 203182 3 22 Tires and Wheels 612344 1697959 1697959 Suspension 15 Dynamically balance the tire using a maximum balance weight of 170 g 6 oz per side Refer to Tire and Wheel Assembly Balancing Off Vehicle in Vibration Diagnosis and Correction 2005 C K Truck Service Manual 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 Tighten Tighten the torx bolts to 53 N m 39 Ib ft 3 Install the hex bolts 1 and tighten Tighten Tighten the hex bolts to 35 N m 26 Ib ft 4 Install the spare tire Refer to Spare Tire Replacement In Vehicle 2005 LSSV Service Manual Supplement Suspension Spare Tire Carrier Replacement Bed Mounted Removal Procedure Caution Be careful not to drop tire
123. earn Procedure with Initiator 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 Tire Monitoring The system consists of wheel mounted sensor transmitters inside each tire which measure contained air pressure and temperature then transmit this data to a receiver within view of the driver System Operation The system operates continuously transmitting air pressure and temperature data Important Use of Chemicals Temporary resealing or reinflation products containing internal sealers or propellants in any tire wheel assembly may adversely affect the operation of the Sensor Transmitters e At approximately 5 minute intervals when the vehicle is moving faster than 10 kph 6 mph unless pressure changes then data is transmitted within seconds Every 15 minutes when the vehicle is parked and pressure drops to 18 psi 124 kPa or lower 2005 LSSV Service Manual Supplement Suspension Tire Pressure Monitoring 3 51 Initiator Programming Programming The initiator is a handheld tool that assists the service technician during installation of the SmarTire system The initiator is designed to interact with a high pressure sensor to provoke a data transmission or to place the sensor in a different state The initiator
124. ecifications 8 48 Repair Instructions 8 49 Front Pull Winch Receiver Replacement 8 49 Front D Ring Replacement Ambulance Maintenance Body 8 50 Front D Ring Replacement LSSV 8 50 Rear D Ring Replacement Maintenance Body 9 5 Rear D Ring Replacement LSSV 8 52 Front D Ring Bracket Replacement 8 52 Rear D Ring Bracket Replacement Maintenance Body 8 53 Rear D Ring Bracket Replacement LSSV 8 54 D Ring Bracket Crossmember Replacement Maintenance Body 8 54 Upper Radiator Support Reinforcement 8 55 Lower Radiator Support Reinforcement 8 56 Front Skid Plate Replacement 8 56 Rear Skid Plate Replacement 8 57 Front Support Beam Replacement 8 58 Center Support Beam Replacement 8 58 Rear Support Beam Replacement 8 59 Rear Frame Bracket Replacement 8 60 Fuel Tank Skid Plate Replacement 8 60 Trailer Hitch Reinforcement Plate Replacement Maintenance Body 8 62 8 2 Table of Contents Horns Schematic and Routing Diagrams Horn Schematics Diagnostic Information and Procedures Symptoms aT Horns Inoperative in Blackout BO A nee Horns Operate In Blackout B O Mode Descript
125. ections are clean prior to installation E 2 Position the slave receptacle harness onto the bumper assembly Install the 3 clamps and the fasteners onto the slave receptacle harness and the blackout B O harness Connect the slave receptacle connectors to the slave receptacle Refer to Slave Receptacle Replacement LSSV or Slave Receptacle Replacement Ambulance Maintenance Body Install the positive slave receptacle cable in the same routing location as removed Connect the positive slave receptacle cable connector 1 to the 24V battery connection Install the negative slave receptacle cable in the same routing location as removed Connect the negative slave receptacle connector 2 to the cable ground connection Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure 2005 LSSV Service Manual Supplement Engine Electrical 6 45 1706974 1706974 1706972 6 46 Engine Electrical 1706968 1706663 1706663 Engine 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 connectio
126. ectrical Auxiliary Lamp Extension Harness 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 Access the auxiliary rear lamp extension harness from the engine compartment at the left side of the bulkhead 3 Remove the connector 1 from the I P auxiliary harness and wiring harness straps 2 connecting to the lamp harness Caution To avoid any vehicle damage serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist support the vehicle with jack stands at the opposite end from which the components are being removed Caution Refer to Vehicle Lifting Caution in Cautions and Notices 4 Raise and support the vehicle on a hoist Refer to Lifting and Jacking the Vehicle in General Information in the 2005 C K Truck Service Manual 5 Trace the auxiliary rear lamp harness extension along the path of the existing harness and vehicle frame 6 Remove the connector to the rear lamp harness 2005 LSSV Service Manual Supplement Wiring Systems 8 185 1704995 1704991 8 186 Wiring Systems 1704991 749941 1704992 Body Installation Procedure Install the connector to the rear lamp harness Install the auxiliary rear lamp harness extension along the path of the ex
127. ems 8 175 C308M Relay Interrupt Harness to I P Harness 153645 258179 e 12129081 Connector Part Connector Part e 12129155 e 2 Way F Flex Lock i s Information Information 2 i 280 Series BK 2 Way M MIP 280 Series BK Circuit Circuit Wire Color No Wire Color No Blackout B O Service Blackout B O Service ER S BK 150 Ground B 180 1391785 1708840 Connector Part 12015791 Connector Part 12010996 Information 1 Way F Weather Pack BK Information e 1 Way M Weather Pack BK Circuit Circuit Wire Color No Wire Color No Supply Voltage Supply Voltage to Relay Module dis 912 to Relay Module 2005 LSSV Service Manual Supplement 8 176 Wiring Systems Body C900M Blackout B O and Trailer Harness to Transfer Connector Harness 593204 888059 Connector Part dic Connector Part enims TWR BK TWR BK Circuit Wire Color No Blackout B O Marker Pers Vel Wire Color Blackout B O Marker Lamps 150 L wlee n 593204 888059 Connector Part ili Connector Part Misa ac yi pa Wire Color Wire Color B 17367 Blackout B O Stoplamps sel ei Blackout B O Stoplamps DGN 19 S T Lamps Right C DGN 19 S TLamps Right 2005 LSSV Service Manual Supplement Body Wiring Systems 8 177 C902M Blackout B O and Trailer Harness to Rear Blackout B O Lamp 781760 258174 Connector Part ie Connector Part vie Information s 2 Way F Weather Pack information e 2 Way M Weather
128. ent 8 121 2005 LSSV Service Manual Supplement Body Commercial Trailer Connector Replacement LSSV Commercial Trailer Connector Replacement Maintenance Body Military Trailer Connector Replacement LSSV Military Trailer Connector Replacement Maintenance Body Headlamp Replacement Blackout B OES V m Headlamp Replacement Blackout B O Ambulance Maintenance Body Headlamp Bulb Replacement Blackout B O Marker Lamp Replacement Front Blackout B O LSSV Marker Lamp Replacement Front Blackout B O Ambulance Maintenance Body Rear Marker Lamp Replacement Maintenance Body Blackout B O Taillamp Replacement LSSV ees Blackout B O Taillamp Replacement Maintenance Body Taillamp Blackout B O Lamp Replacement MR aed Taillamp Replacement Maintenance Body Taillamp Bulb Replacement Maintenance Body License Plate Lamp Replacement LSSV License Plate Lamp Replacement Maintenance Body License Plate Lamp Replacement Ambulance Body License Plate Lamp Bulb Replacement Ambulance Body License Plate Lamp Bulb Replacement Mainte
129. epair the source of the overload and replace fuse Go to Step 17 Go to Step 6 Test the ground circuit of the inoperative bulb for high resistance or an open Did you find and correct the condition Go to Step 17 Go to Step 13 Connect a test lamp between connector C1 cavity C of the junction block rear lamps and ground Does the test lamp illuminate Go to Step 7 Does the test lamp illuminate Go to Step 8 Locate and repair the open or high resistance in the ground circuit Did you complete the repair Go to Step 17 Connect a test lamp between cavity 30 of the interrupt relay and ground Does the test lamp illuminate Go to Step 10 Locate and repair the open in circuit 24 Did you complete the repair Go to Step 17 Connect a test lamp between cavity 87 of the interrupt relay and ground Does the test lamp illuminate Go to Step 9 Go to Step 13 Go to Step 11 k Go to Step 14 Go to Step 12 Connect a test lamp between cavity F of the backup lamp switch and ground Does the test lamp illuminate Go to Step 15 Replace the bulbs Did you complete the replacement Go to Step 17 Go to Step 16 Replace the interrupt relay Locate and repair the open or high resistance in circuit 1524 or 24 Did you complete the repair Go to Step 17 Replace the backup lamp switch Did you complete the replacement Go to Step 17 Did you correct the condition system OK 13 14 15 16 7 4
130. er Connector Replacement Maintenance Body in Lighting Systems Install the commercial trailer connector 3 Refer to Commercial Trailer Connector Replacement LSSV or Commercial Trailer Connector Replacement Maintenance Body in Lighting Systems Install the trailer wiring harness Refer to 12V and 24V Harness Replacement Maintenance Body in Wiring Systems Using the aid of an assistant position the rear bumper onto the vehicle by sliding it on to the tie down plates Notice Refer to Fastener Notice in Cautions and Notices 8 Install the 4 bumper bolts 1 right side shown left side similar Tighten Tighten the bumper bolts to 79 N m 59 Ib ft Connect the trailer wiring harness Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Install the D rings Refer to Rear D Ring Replacement Maintenance Body or Rear D Ring Replacement LSSV in Frame and Underbody 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 Remove the swing away spare tire carrier latch 2 if equipped Refer to Spare Tire Carrier Latch Replacement Swing Away in Tires and Wheels Remove the rear D ring brackets 3 Refer to Rear D Ring Bracket Replacement Maintenance Body or Rear
131. er l J l within 5 minutes of driving RF Section Malfunction contact dealer DTC E2 Conditions for Setting the DTC The following may help identify the problem better This DTC indicates that there is a problem with the Power the unit OFF and ON data in the receiver and on display units Causes If the DTC has cleared Operating with the incorrect of this DTC can include settings Contact dealer Corrupted custom profile If the DTC persists Receiver or display may have Corrupted factory profile to be replaced DTC E2 DTC Symptom Action s Receiver and or display EEPROM Fault Contact Dealer 2005 LSSV Service Manual Supplement Suspension Tire Pressure Monitoring 3 37 DTC E3 Conditions for Setting the DTC These DTCs will usually represent an internal fault Try powering the unit OFF and ON to clear these DTCs If these DTCs continuously occur the unit may have to be replaced DTC E3 DTC Receiver andlor display Oscillator Fau DTC E4 Conditions for Setting the DTC These DTCs will usually represent an internal fault Try powering the unit OFF and ON to clear these DTCs If these DTCs continuously occur the unit may have to be replaced DTC E4 DTC Symptom Action s Receiver and or display Internal Bus Fault Contact Dealer 2005 LSSV Service Manual Supplement 3 38 Tire Pressure Monitoring 1692811 1692811 Suspension Repair nstructions Tire Pressure Monitoring Receiver Replacement
132. er pieces 1 5 7 Ensure that the tab in cover piece 1 fits into the slot in cover piece 5 2 Install bolt 2 at the top of the cover 3 Install shock bolt 8 and nut 3 4 Install bolts 6 and nuts 4 Notice Refer to Fastener Notice in Cautions and Notices 5 Ensure that the contact pad of the jounce shock is aligned with the jounce shock Tighten e Tighten lower shock bolt to 90 N m 70 Ib ft Tighten shock cover bolts to 35 N m 26 lb ft 6 Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual 1700957 2005 LSSV Service Manual Supplement 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 Two identical direct dual action shock absorbers and hydraulic jounce bumpers provide the ride control The jounce bumpers are frame mounted Rear Shock Absorber Description The suspension features a heavy duty shock absorber package necessary for off road conditions A shock absorber is a base hydraulic cyl
133. ery Charging Optima Engine Battery Inspection Test Optima Diagnostic Aids Caution Refer to Battery Disconnect Caution in Cautions and Notices Important e Verify that all battery connections are clean and torqued to fastener specification Use the Out of Vehicle test for each battery in the system Follow these instructions in order to avoid an incorrect diagnosis 1 Disconnect the negative battery cables Refer to the Battery Cable Disconnect Connect Procedure 2 Install the test adapters on the terminals 3 Follow the instructions for testing a removed battery Important Use the correct terminal adapters Do not use any common bolts or a combination of bolts of nuts and of washers as adapters when testing the battery Use the test adapters that are provided with the J 42000 or GM P N 12303040 terminal adapters If the adapters that are provided with the J 42000 require replacement use GM P N 12303040 Any other adapter may not contact the correct areas of the battery terminal causing a resistance that may result in an invalid battery test result 4 Replace the battery only if the second test shows a REPLACE BATTERY or BAD CELL REPLACE result Battery Charging Optima Tools Required J 42000 Battery Tester e Only use a voltage regulated charger e The charging area should be well ventilated Do not charge a battery that appears to be frozen allow the battery to warm to room temperature and test
134. ess and Connector Replacement in Engine Electrical 4 Install the D Rings to the vehicle Refer to Front D Ring Bracket Replacement in Frame and Underbody 1698261 Bumper 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 blackout B O headlamp Refer to Headlamp Replacement Blackout B O LSSV or Headlamp Replacement Blackout B O Ambulance Maintenance Body in Lighting Systems 3 Remove the slave receptacle Refer to Slave Receptacle Replacement LSSV or Slave Receptacle Replacement Ambulance Maintenance Body in Engine Electrical 1700940 2005 LSSV Service Manual Supplement Body 4 9 Remove the blackout B O marker lamp Refer to Marker Lamp Replacement Front Blackout B O LSSV or Marker Lamp Replacement Front Blackout B O Ambulance Maintenance Body in Lighting Systems Remove the 3 bolts and the 3 clamps securing the slave receptacle harness and the blackout B O harness to the bumper assembly Remove the winch connector Refer to Front Winch Harness and Connector Replacement in Engine Electrical Support the bumper assembly using an approved support system Remove the 2 bolts from the upper bumper supports Remove the 4 bolts from the lower supports 2005 LSSV
135. essure Indicator 10 Units of Pressure or Temperature 5 Alert Indicator 11 Numerical Display 6 Learn Mode 12 Towing Vehicle Indicator 2005 LSSV Service Manual Supplement 3 34 Tire Pressure Monitoring Suspension Switch Panel 1692802 Legend 1 Learn Mode 3 Mode Button 2 Set Button 4 System Switch Panel 2005 LSSV Service Manual Supplement Suspension Tire Pressure Monitoring 3 35 Programming Initiator LF INITIATOR INITIATE DE ENERGIZE 1693366 Legend 1 Programming Initiator 4 Learn Button 2 Status LED 5 De Energize Button 3 ON OFF Switch 6 Initiate Button 2005 LSSV Service Manual Supplement 3 36 Tire Pressure Monitoring Suspension Tire Pressure Monitoring System Receiver Connector End Views Monitoring Gage 1700097 Connector Part e 174823 1 Information 4 Way F WH Circuit Wire Color 1 R 243 Battery Positive Voltage 1050 34 NotUsed Connector Part e 12047785 Information s 4 Way F Metri Pack 150 BK Circuit Wire Color No R 243 Battery Positive Voltage 1050 Instrument Panel Lamps D NtUsed 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 DIC E1 li If no transmission received l e Not Transmittin L ae E1 Sensor s receiv
136. et 1 Refer to License Plate Bracket Replacement 9 Install the license plate lamp 2 Refer to License Plate Lamp Replacement LSSV or License Plate Lamp Replacement Maintenance Body or License Plate Lamp Replacement Ambulance Body in Lighting Systems 10 Install the rear step pads Refer to Step Pad Replacement Rear Bumper 1698272 11 Install the rear blackout B O taillamps 1 Refer to Blackout B O Taillamp Replacement LSSV or Blackout B O Taillamp Replacement Maintenance Body in Lighting Systems 12 Install the rear D ring brackets 3 Refer to Rear D Ring Bracket Replacement Maintenance Body or Rear D Ring Bracket Replacement LSSV in Frame and Underbody 13 Install the swing away spare tire carrier latch 2 if equipped Refer to Spare Tire Carrier Latch Replacement Swing Away in Tires and Wheels 14 Install 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 1698269 2005 LSSV Service Manual Supplement 8 46 Exterior Trim Body Exterior Trim Specifications Fastener Tightening Specifications Specification Application Metric Rear Mud Guard Brace Bolts 18 Ib ft Rear Mud Guard Screws 4 N m 35 Ib in 2005 LSSV Service Manual Supplement Body Repair Instructions Guard Mud Rear One or Both Replacement Removal Procedure Caution Refer to Vehicle Lifting
137. et the bracket 1 to the elecirical center cover 2 Install the vehicle load disconnect switch if equipped Refer to Vehicle Load Disconnect Switch Replacement LSSV Maintenance Body or Vehicle Load Disconnect Switch Replacement Ambulance in Engine Electrical 1704992 3 Set the electrical center block in its resting position until the tabs 3 lock into place 4 Install the electrical center cover assembly 1 5 Install the top cover 2 6 Install the fender upper brace Notice Refer to Fastener Notice in Cautions and Notices 7 Install the upper brace fasteners Tighten Tighten the fasteners to 25 N m 18 lb ft 8 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 749941 2005 LSSV Service Manual Supplement 8 188 Wiring Systems 1704994 1704994 Body 12V and 24V Harness Replacement Maintenance Body 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 Disconnect the 12V and the 24V harness connector 1 from the blackout B O and the trailer harness connectors Disconnect the license plate lamp connector 2 from the license plate lamp Disconnect the blackout B O connector 3 from the blackout B O and trailer harness connector Remove the 12V to 24V
138. f the 2005 C K Truck Service Manual Leak test the fittings of the component using the J 39400 A 2005 LSSV Service Manual Supplement Body Body Replacement Maintenance Body 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 Caution Refer to Vehicle Lifting Caution in Cautions and Notices 2 Raise the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual 3 Disconnect the wiring harness for the maintenance body 4 Remove the fuel fill hose bracket bolt 1 5 Remove the fuel tank filler housing to fuel tank fill pipe bolts 1 6 Remove the ground wire bolt 1 for the fuel filler hose 2005 LSSV Service Manual Supplement Body Rear End 8 23 1701836 1701829 1701837 8 24 Body Rear End 1703185 1703185 1701837 Body 7 Remove the maintenance body fasteners from the body mounis 8 Lift and remove the maintenance body 1 from the chassis Installation Procedure 1 Align the maintenance body 1 on the frame rails Notice Refer to Fastener Notice in Cautions and Notices 2 Loosely install the maintenance body fasteners to the body mounts Tighten Tighten the retaining bolts to 80 N m 59 Ib ft Important Clean any existing corrosion or paint f
139. fting up off of the mounting posts 1698260 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 Ib ft 3 Install the center brush guard Refer to Center Radiator Grille Brush Guard Replacement 1698260 Radiator Grille Brush Guard Replacement The grille brush guard and front bumper on the ambulance maintenance body are replaced as a unit If damaged refer to Bumper Replacement Front 1700949 2005 LSSV Service Manual Supplement 8 30 Bumpers Body Center Front Bumper Replacement Removal Procedure 1 Remove the D Rings Refer to Front D Ring Bracket Replacement in Frame and Underbody 2 Remove the front winch power disconnect if equipped Refer to Front Winch Harness and Connector Replacement in Engine Electrical 3 Remove the upper 4 bolts 1 from the bumper 4 Remove the lower 4 bolts 2 from the bumper and remove from vehicle 1698261 Installation Procedure 1 Install the center bumper onto the frame brackets and install upper bolts 1 Notice Refer to Fastener Notice in Cautions and Notices 2 Install the lower bolts 2 and tighten all bolts Tighten Tighten bumper bolts to 88 98 N m 65 72 lb ft 3 Remove the front winch power disconnect if equipped Refer to Front Winch Harn
140. harness from the vehicle Installation Procedure 1 Install the 12V to 24V wiring harness in the same routing location as removed Connect the blackout B O connector 3 from the 12V and 24V harness to the blackout B O and trailer harness connector Connect the license plate lamp connector 2 from the 12V to 24V harness to the license plate lamp Connect the 12V to 24V harness connector 1 to the blackout B O and the trailer harness connector Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2005 LSSV Service Manual Supplement SERVICE MANUAL Light Service Support Vehicle ESSV enhanced Mobility Package EMP
141. he clamp and using a twisting motion remove the inlet heater hose 1 from the coolant booster pump 1701828 17 Squeeze the plastic retainer tabs on the inlet hose The hose connection is located at the bulkhead 12777 2005 LSSV Service Manual Supplement 8 18 Body Rear End 12778 1701829 1701830 Body 18 Remove the outlet hose from the vehicle engine compartment and under body Note routing location of hose for reassembly 19 Remove any wiring harness straps or clamps Do not remove the hoses from the ambulance body 20 Remove the fuel tank filler housing to fuel tank fill pipe bolts 1 Repeat step for other fuel fill 21 Remove the nut and bolt 1 from the ground strap 2005 LSSV Service Manual Supplement Body Body Rear End 8 19 22 Remove the upper nut 1 lower mount 2 and lower bolt 3 of the body mount Repeat this step for the remaining mounts 1701831 23 Lift and remove the ambulance body 1 and upper mount 2 from the vehicle 1701833 Installation Procedure 1 Align the ambulance body 1 and the upper mounts 2 on the frame rails 1701833 2005 LSSV Service Manual Supplement 8 20 Body Rear End Body Notice Refer to Fastener Notice in Cautions and Notices 2 Loosely install the lower bolt 3 lower mount 2 and the nut 1 Repeat this step for the remaining mounis Tighten Tighten the retaining bolts to the frame rail to
142. hematic Reference Exterior Lights Schematics and Interior Lights Schematics Did you review Blackout B O Lighting Description and Operation Go to Blackout B O 1 Lighting Circuit Go to Step 2 Operation Place blackout B O drive lamp switch in OFF mode Connect a test lamp between blackout B O drive lamp switch cavity B circuit 901 TN WH to ground Does the test lamp illuminate Go to Step 3 Go to Step 4 Replace blackout B O drive lamp switch Refer to Blackout B O Switch Replacement Did you complete the replacement 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 Go to Step 5 5 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 Headlamps Operate in Blackout B O Mode Stp Ae 0 Yes X No Schematic Reference Exterior Lights Schematics and Interior Lights Schematics Did you review Blackout B O Lighting Description and Operation Go to Blackout B O 1 Lighting Circuit Go to Step 2 Operation 1 Place blackout B O service switch into the blackout B O mode 2 Connect a test lamp from cavity 85 at the blackout B O lighting drive relay and ground Does the test lamp illuminate Go to Step 4 Go to Step 3 Replace blackout B O drive relay Did you complete the replacement Go to Step 5 Replace blackout B O serv
143. hicle Load Disconnect Switch Replacement LSSV Maintenance Body 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 disconnect switch key and the left upper brace 3 Remove the electrical center cover assembly 1 by lifting the cover outwards to clear the tabs 3 4 Remove the switch mounting nuts and bolts 5 Remove the nuts holding the 24V and 12V cables to the switch and remove the cables Note location of cables removed for assembly 2005 LSSV Service Manual Supplement Engine 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 Tighten Tighten the cable mounting nuts to 9 N m 80 Ib in Red cable from 24V battery positive 1 to terminal 4 Red black cable 4 from 24V generator to terminal 3 Red cable 3 from UBEC to terminal 1 Red cable 2 from 24V battery negative to terminal 2 2 Install the switch to the underhood electrical center cover Tighten Tighten the switch mounting nuts to 9 N m 80 Ib in 3 Set the electrical center cover assembly in its resting position until the tabs 3 lock into place 4 Install the fender upper brace and the disconnect switch key 5 Connect the battery cables Refer to Battery Cable Disconnect
144. hten Tighten the nut to 10 N m 89 Ib in 2005 LSSV Service Manual Supplement Lighting Systems 8 125 1706995 1692745 1692745 8 126 Lighting Systems Body Headlamp Replacement Blackout B O Ambulance Maintenance Body Removal Procedure 1 Remove the nut and washer 3 from the lamp stud at the base of the mounting bracket 2 Remove the ground lead 4 by sliding it off the stud 3 Disconnect the auxiliary wiring harness connector 2 from the headlamp 4 Remove the blackout B O lamp assembly 1 from the mounting bracket 1693484 Installation Procedure 1 Install the blackout B O lamp assembly 1 to the mounting bracket 2 Connect the auxiliary wiring harness connector 2 3 Install the ground lead 4 by sliding it on the stud Notice Refer to Fastener Notice in Cautions and Notices 4 Install the washer and nut 3 to the lamp stud Tighten Tighten the nut to 10 N m 89 Ib in 1693484 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 1693473 2005 LSSV Service Manual Supplement Body Installation Procedure Important Use a standard 1073 bulb for replacement 1 Install the new bulb in the lamp socket Important The O ring insta
145. i ye va Lighting Systems 0 8 i Gage Gage Lamp E I B YE i 150 BK 0 8 I G101M i S301M E 1702791 ouiDu3 2914199J3 euiDu3 C L 9 jueuiejddng jenuey 891449S ASST 5002 Starting and Charging Schematics Winch Prep Wiring Schematics L Oc Bulkhead 5 BATT BATT BATT Junction Es e Ql ey em MN ie l l Battery Schematics 32 RD 13 RD l ust 13 Junction Block BK i 1 Underhood B Rear Winch 1702 92 29141993 euiDu3 Y L 9 ouiDu3 Engine Engine Electrical 6 15 Component Locator Engine Electrical Component Views 24V Slave Start Receptacle Assembiy Ambulance Maintenance Body 1704693 Legend 1 Battery Negative Ground Black 3 Slave Start Receptacle Cover 2 Battery Positive Ground Red 4 Slave Start Receptacle 2005 LSSV Service Manual Supplement 6 16 Engine Electrical Engine 24V Slave Start Receptacle Assembiy LSSV 1703355 Legend 1 Battery Negative Cable 4 Slave Start Receptacle 2 Mounting Bracket 5 Battery Positive Cable 3 Slave Start Receptacle Cover 2005 LSSV Service Manual Supplement Engine Engine Electrical 6 17 Bulkhead Junction Block 1703356 Junction Block Jumper Plate 1 Negative Winch Prep Cable Rear 2 3 Ground Connection 4 5 6 Positive Winch Prep Cable Rear 8 Battery Positive Cable Right Mounting Bracket 9 Battery Positive Cable Frame Mounted Battery Negati
146. ice switch Refer to Blackout B O Switch Replacement Did you complete the replacement Go to Step 5 8 5 emoe Goto sone Did you correct the condition System OK Go to Step 2 2005 LSSV Service Manual Supplement Body Lighting Systems 8 109 Blackout B O Stoplamps Inoperative Sep h Acton Ye TN Schematic Reference Exterior Lights Schematics and Interior Lights Schematics Did you review Blackout B O Lighting Description and Operation Go to Blackout B O 1 Lighting Circuit Go to Step 2 Operation Observe the stoplamps while pressing the brake pedal Go to Testing for Does the system operate normally Electrical intermitients in Wiring Systems in 2005 C K Truck Service Manual Go to Step 3 Inspect the fuse s check for damaged or corroded inline connectors check for broken or partially broken wires inside insulation and properly installed aftermarket equipment Did you find the condition Go to Step 4 Go to Step 5 Make necessary repairs Did you complete the repairs Go to Step 15 Are all the stoplamps inoperative Go to Step 6 1 Disconnect blackout B O service lamp switch 2 Connect test lamp between circuit 913 WH cavity D wire and ground 4 9 Go to Step 8 Does the test lamp illuminate Locate and repair the open or high resistance in circuit 913 Did you correct the condition Go to Step 15 Test the supply voltage circui
147. ights Schematics Did you review Blackout B O Lighting Description and Operation Go to Blackout B O Lighting Circuit Go to Step 2 Operation 1 Place the blackout B O service switch in blackout B O mode 2 Connect a test lamp at cavity C of the blackout B O switch and ground Does the test lamp illuminate Go to Step 3 Go to Step 6 1 Disconnect the blackout B O service switch connector from the switch 2 Connect a test lamp at cavity C of the connector and ground Does the test lamp illuminate Go to Step 5 Go to Step 4 Locate and repair the short to voltage on circuit 912 OG pv Did you complete the repair Go to Step 9 Remove the CTSY 1 interrupt relay from the relay module La see Di you compre mo reprenen eses Did you complete the replacement Go to Step 9 Locate and repair the short to voltage on circuit 690 GY BK ew Did you complete the repair Go to Step 9 Operate the system in order to verify the repair D un mu Did you correct the condition System OK Go to Step 2 Turn Signals Operate in Blackout B O Mode Sep 1 Acion No Schematic Reference Exterior Lights Schematics and Interior Lights Schematics Did you review Blackout B O Lighting Description and Operation Go to Blackout B O Lighting Circuit Go to Step 2 Operation 1 Place the blackout B O service switch in blackout B O mode 2 Connect a test lamp at cavity C of the
148. il over the adapter plates with the 2 outer bolts and the 2 upper facing bracket bolts and nuts Tighten e Tighten the 2 outer bolts to 26 N m 19 Ib ft e Tighten the 2 upper facing bolts to 8 N m 70 Ib in 4 Install side rail adapter plates front and rear by aligning the bolt holes to the holes in the box 5 Install the troop seats 1 Refer to Seat Replacement Troop in Seats 6 Install the side struts top bows 2 and cargo cover Refer to Cargo Cover Top Bows Replacement and Cargo Cover Strut Replacement 2005 LSSV Service Manual Supplement Body Rear End 8 11 1703181 1703179 1701838 8 12 Body Rear End 1703181 1703181 1703181 Body Cargo Cover Front End Rail Replacement Removal Procedure 1 Remove the cargo cover from the front of the cargo cover assembly Refer to Cargo Cover Replacement 2 Remove the 4 bolts from the front end rails as needed 3 Remove the 4 rivnuts by drilling out if damaged 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 Tighten Tighten
149. inder The shock is filled with oil and has a moveable shaft that connects to a piston inside the shock absorber Valves inside the shock absorber offer resistance to oil flow and consequently inhibit rapid movement of the piston and shaft The shocks are angle mounted between the frame and the brackets which are attached to the axle tubes 2005 LSSV Service Manual Supplement Rear Suspension 3 13 Rear Shock Absorber Cover Description The suspension features heavy duty shock absorber covers that protect the shock absorber against damage from severe off road usage while providing full function suspension Rear Hydraulic Jounce Bumper A hydraulic jounce bumper is a basic hydraulic cylinder The hydraulic jounce bumper aids the shock absorber in increased energy absorption and improved endurance The jounce bumper is mounted to the frame above the rear axle 3 14 Tires and Wheels Suspension Tires and Wheels Specifications Fastener Tightening Specifications Specification Application oo English 81 Nim 102 108 Nm 35 Nm 25 Nem a7 Nm 68 Nem a7 Nm Spare Tire Carrier Torx Bolts In Vehicle 53 N m 90 Nem 50 Nem 2005 LSSV Service Manual Supplement Suspension Tires and Wheels 3 15 Component Locator Tires and Wheels Component Views Beadlock Wheel 1697955 Legend 1 Rear Half of Wheel 5 Front Half of Wheel 2 Beadlock 6 Tire Pressure Monitor Sensor and 3 Tire Retaining Clip 4
150. ining Procedure Caution To avoid being burned do not remove the radiator cap or surge tank cap while the engine is hot The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot 1 Follow the steps below in order to remove the surge tank fill cap 1 1 Slowly rotate the cap counterclockwise 1 2 Stop rotating and allow the hissing to stop 1 3 After all the hissing stops continue turning counterclockwise in order to remove the cap Caution Refer to Vehicle Lifting Caution in Cautions and Notices 2 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual 3 Place a drain pan under the lower radiator hose 4 Using the J 38185 reposition the lower radiator hose clamp 5 Remove the lower radiator hose from the radiator 6 Remove the supply hose 1 at the rear of the coolant booster pump 7 Drain the cooling system 8 If a complete engine block drain is required remove the left and right engine block coolant drain plugs 2005 LSSV Service Manual Supplement Engine 9 Remove the engine block coolant heater if equipped Refer to Coolant Heater Replacement 10 Inspect the coolant 11 Follow the appropriate procedure based on the condition of the coolant e Normal in appearance Follow the filling procedure Disc
151. ion and Operation Horn with Blackout B O Control Circuit Operation Instrument Panel Gages and Console Specifications Fastener Tightening Specifications Schematic and Routing Diagrams Instrument Cluster Schematics Componentlocator Instrument Panel Gages and Console Component Views Instrument Panel Gages and Console Connector End Views Diagnostic Information and Procedures Symptoms Instrument Panel Gages cskeci Voltmeter Gage Inaccurate or Inoperative Repair Instructions Voltmeter Gage Replacement Accessory Instrument Panel I P Replacement eee Air Filter Restriction Gage Replacement Air Filter Restriction Gage Hose Replacement A A peras Air Filter Restriction Gage Adapter Replacement Description and Operation Instrument Panel I P Gages lt lt e MA AM Air Filter Restriction Gage Description Interior Trim EEE cetus EE iam Specifications Fastener Tightening Specifications Repair Instructions
152. isting harness and vehicle frame Remove supports and lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in the 2005 C K Truck Service Manual Install the connector 1 to the I P auxiliary harness and wiring harness straps 2 holding to the lamp harness Install the auxiliary rear lamp extension harness to the engine compartment location at the left side of the bulkhead Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Relay Mounting Bracket Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 BEM Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Remove the left fender upper brace Removetop cover 2 Remove the electrical center cover assembly 1 by lifting the cover outwards to clear the tabs 3 Remove the vehicle load disconnect switch if equipped Refer to Vehicle Load Disconnect Switch Replacement LSSV Maintenance Body or Vehicle Load Disconnect Switch Replacement Ambulance in Engine Electrical Caution Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury 6 Drill out the rivets 2 and remove bracket 1 2005 LSSV Service Manual Supplement Body Wiring Systems 8 187 Installation Procedure 1 Riv
153. jenuey 891449S ASST 5002 Exterior Lights Schematics Trailer Wiring y y 902 GN WH 900 1 0 BN WH 0 8 150 BK 1 0 150 BK 1 0 30 86 30 86 24V to 24V to Blackout Blackout Relay Relay 87 85 87 85 87 87 RD RD 2 0 2 0 30 GN 0 8 30 BN 1 0 150 BK 0 8 S905M N 150 BK 0 8 19 D GN 0 8 AN KP 18 YE 0 8 hi 87 RD 2 0 150 BK C909M A 901M A B m dM us 150 0 8 dm 900M TA B C BK 802 0 8 RD 12 Pin 2 0 Trailer Connector G901M Fr 1693291 suiejs s DunuDr1 76 8 pog jueuiejddng enuey 891449 ASST 5002 802 RD 2 0 916 GN 19 BK 1 0 1 0 30 86 Right Turn Relay 87 85 916 GN 1 0 802 RD 2 0 Charging Schematics in Engine Electrical Exterior Lights Schematics Rear Relay Harness 802 RD 2 0 S908M 802 RD 2 0 802 RD 2 0 915 V Manas 18YET0 19BK1 0 BN 19 BK 1 0 1 0 30 86 Park Left Helay Turn 1 0 30 86 Relay 87 85 18 YE 1 0 915 BN 1 0 ee License Plate Lamp in External Lighting Ground Distribution Schematics in Wiring Systems Production Harness Refer to the 200 C K Truck Service Manual m t I C906 Production Harness Refer to the 2005 C K Truck Service Manual 1693292 Apog 66 9 Ssuajs4s Buny ry jueuiejddng jenuey 8914495 ASST 5002 Interior Lights Schematics Topper Wiring 912 OG 1 0 C Topper Lamp Switch A B 800 1803 BN j BN WH 1 0 1 0 C301M G
154. ket Remove the bracket nuts 2 Remove the bracket bolts 1 Remove the mounting bracket oe SS i 1702783 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 Ib in 3 Install the nuts 2 onto the stud Tighten Tighten the nut to 13 N m 10 Ib ft 4 Install the vehicle jack in the bracket 5 Lower the rear seat 1702783 Enhanced Mobility Package Jack Mounting Bracket Replacement Crew Cab Removal Procedure Raise up the rear passenger seat Hemove the vehicle jack from the bracket Remove the rear bracket bolts 1 Remove the mounting bracket D OBI 1702784 2005 LSSV Service Manual Supplement 8 88 Interior Trim Body 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 Tighten Tighten the bolt to 9 N m 80 Ib in 3 Install the vehicle jack in the bracket 4 Lower the passenger rear seat 1702784 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 1702786 Installation Procedure 1 Install the mount bracket in the mounting position Notice Refer t
155. kup Lamps a m Supply Voltage ES BK Ground B Trailer Auxiliary dd Supply Voltage 1619 S T Lamps Right LB RD 74 7 J YE ve 16 Battery Positive Voltage Park Lamps S T Lamps Left 525095 1535465 e 7 Way F Metri Pack 280 Sealed BK Circuit Wire Color No Trailer Backup Lamps 1750 Ground f B Trailer Auxiliary 1619 S T Lamps Right D RD 742 Battery Positive Voltage E TF Park Lamps 1618 S T Lamps Left C E 2005 LSSV Service Manual Supplement Connector Part Information Connector Part Information 366087 e 15317327 e 7 Way M Metri Pack 280 Sealed BK Circuit Wire Color No Trailer Backup Lamps 1750 47 Trailer Auxiliary Supply Voltage 1619 S T Lamps Right Battery Positive Voltage 6 Park Lamps S T Lamps Left 366087 e 15317327 e 7 Way M Metri Pack 280 Sealed BK Circuit Wire Color No Trailer Backup Lamps 1024 Supply Voltage 1750 47 Trailer Auxiliary Supply Voltage 1619 S T Lamps Right Battery Positive Voltage N Park Lamps B YE 1618 S T Lamps Left 8 180 Wiring Systems Body C909M Rear Blackout B O and Trailer Harness to 12 24V Trailer Harness 1391785 1708840 Connector Part 12015791 Connector Part 12010996 Information 1 Way F Weather Pack BK Information e 1 Way M Weather Pack BK Circuit Circuit Wire Color N Wire Color No o A RD 87 Power to Trailer Relays A RD 802
156. l Supplement 8 72 Instrument Panel Gages and Console Body Accessory Instrument Panel I P Replacement Removal Procedure Caution Refer to Battery Disconnect Caution 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2 Remove the fasteners 1 from the panel 3 Move the panel 2 out far enough to gain access to the harness connections 1694852 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 Refer to Blackout B O Switch Replacement in Lighting Systems or Voltmeter Gage Replacement or Air Filter Restriction Gage Replacement 1694853 Installation Procedure 1 Install the parts removed from the accessory in S panel Refer to Blackout B O Switch oO ei Replacement in Lighting Systems or Voltmeter m UD Gage Replacement or Air Filter Restriction Gage a 2 Replacement eS 2 Install the connectors 1 to the blackout B O S switches 3 Install the connector and bulb 3 to the voltmeter gage 4 Connect the air line 2 on to the air filter restriction gage 1694853 2005 LSSV Service Manual Supplement Body 5 Install
157. l in the brake master cylinder reservoir 2 If the fluid level is midway between the maximum full point and the minimum allowable level no fluid needs to be removed from the reservoir before proceeding 3 f the fluid level is higher than midway between the maximum full point and the minimum allowable level remove fluid to the midway point before proceeding 4 Remove the tire and wheel assembly Refer to Tire and Wheel Removal and Installation in Pere Tires and Wheels in the 2005 C K Truck Service Manual 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 e Slowly tighten the C clamp until the pistons are pushed completely into the caliper bores e 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 Notice Refer to Brake Caliper Notice in Cautions and Notices in 2005 C K Truck Service Manual 9 Remove the caliper bracket 1 and brake caliper as an assembly 794150 2005 LSSV Service Manual Supplement 5 6 Disc Brakes L Leas LI 1702787 1702787 Brakes 10 Remove the caliper bolts from the caliper bracket DO NOT disconnect the hydraulic brake hose from the caliper Installation Procedure 1 Install the b
158. lackout B O Blackout B O Headlamp 1708840 12010996 1 Way M Weather Pack BK Circuit Wire Color No Blackout B O Headlamp Connector Part Information 8 104 Lighting Systems Blackout B O Lamps Fuse 350882 Connector Part 12010105 Information 2 Way M Weather Pack BK Circuit Wire Color No A BN WH Blackout B O Marker Lamps Signal e mom Blackout B O Controls Supply Voltage Blackout B O Lamps Left Rear 258174 Connector Part 12010973 Information s 2 Way M Weather Pack BK Circuit Wire Color No Blackout B O Stoplamp Blackout B O Marker Lamp Supply Voltage Body Blackout B O Lamps Right Rear 258174 Connector Part 12010973 Information s 2 Way M Weather Pack BK Circuit Wire Color No 902 Blackout B O Stoplamp Supply Voltage Blackout B O Marker E EUIS am Lamp Supply Voltage 1391785 Connector Part 12015791 Information 1 Way F Weather Pack BK Circuit Wire Color No Blackout B O Marker eae 900 Lamps Supply Voltage 2005 LSSV Service Manual Supplement Body Blackout B O Service Switch 1704989 Connector Part e 08917695 Information 6 Way F Series 58 BK Circuit Wire Color N PK 9 Blackout B O Drive Lamp Switch Signal B 00 C OG WH WH Relay Block I P Voltage g Blackout B O Control Signal Circuits DE Stoplamp Switch Signal Blackout B O Eau Stoplamps Signal License Plate Lamp O 11 0 12 y 02 1709553
159. lement 8 172 Wiring Systems Body C301M Fiberglass Top Lamp Switch Harness to Switch Extension Harness 635009 333041 Connector Part e 12052641 Connector Part e 12162000 Information 2 Way F MP 150 Series BK Information 2 Way M MP 150 Series BK Circuit Circuit Wire Color No Wire Color No To Rear Topper From Front Topper EN BN To Rear Topper From Front Topper Dome Switch Dome Switch 153645 200179 e 12129081 Connector Part Connector Part e 12129155 Information 2 Way F Flex Lock Information 2 Way M M P 280 Series BK 280 Series BK Circuit Circuit Wire Color No Wire Color No 17 B B Blackout B O Service Switch Nouse 2005 LSSV Service Manual Supplement Body Wiring Systems 8 173 C304M Volt Gage Harness to Generator Harness 1708837 1708839 Connector Part 02973781 Connector Part 02984883 Information e 2 Way F Series 280 BK Information e 2 Way M Series 280 BK Circuit Circuit Wire Color N Wire Color No ES BN 8008 Volt Gage Supply Voltage 8008 Volt Gage Supply Voltage B BK 150 around B BK 150 Grud C305M MBEC Harness to Relay Interrupt Harness 153645 258179 e 12129081 Connector Part Connector Part e 12129155 e 2 Way F Flex Lock Information M 280 Series BK l 2 Way M M P 280 Series BK Circuit Circuit Wire Color No Wire Color No GY BK 690 CTSY Supply Voltage GY BK 690
160. line Harness Connector End Views Inline Harness Connector End Views Inline Harness Connector End Views Inline Harness Connector End Views Inline Harness Connector End Views Inline Harness Connector End Views Inline Harness Connector End Views Inline Harness Connector End Views Inline Harness Connector End Views Inline Harness Connector End Views Inline Harness C108M 2 Cavities m by underhood C201M Under steering column C301M 2 Cavities Under I P for topper lamp 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 C308M 2 Cavities Under I P for blackout B O switch C900M 3 Cavities Harness Routing Views C901M 3 Cavities Harness Routing Views C902M 2 Cavities Rear bumper for right blackout B O Harness Routing Views marker Connector End Views C903M 2 Cavities il for left blackout B O Harness Routing Views C MM NO Q Q Q r C o X C D S gt b S 3 c m 3 D D 3 D 3 8 162 Wiring Systems Body Master Electrical Component List cont d Locator View C909M 1 Cavity Rear bumper for blackout B O relay Connector End View Inline Harness Connector End Views Inline Harness Connector End Views Inline Harness Connector End Views Inline Harness Connector End Views Inline Harness Connector End Views In the front blackout B O harness front
161. ll and activate pump until coolant starts to flow out of the heater core Deactivate the pump and install return hose at the core Install the coolant pressure cap Start the engine Run the engine at 2 000 2 500 RPM until the engine reaches normal operating temperature Allow the engine to idle for 3 minutes Shut the engine OFF Allow the engine to cool Top off the coolant as necessary Turn on the rear HVAC and set in the full heat position Start the engine Run the engine at 2 000 2 500 RPM until the engine reaches normal operating temperature Allow the engine to idle for 3 minutes Shut the engine OFF Allow the engine to cool Top off the coolant as necessary Inspect the concentration of the engine coolant using the J 26568 Rinse away any excess coolant from the engine engine compartment and the rear HVAC compartment 2005 LSSV Service Manual Supplement Engine Coolant Heater Replacement Removal Procedure 1 Drain the cooling system Refer to Draining and Filling Cooling System Ambulance Body 2 Remove the right front tire and wheel Refer to Tire and Wheel Removal and Installation in Tires and Wheels in 2005 C K Truck Service Manual 3 Remove the right engine mount Refer to Engine Mount Replacement Right in Engine Mechanical 6 6L LLY in 2005 C K Truck Service Manual 4 Disconnect the engine coolant heater cord 5 Loosen the
162. ll nuts 2 Tighten Tighten the nuts to 27 N m 20 Ib ft 1693478 Taillamp Bulb Replacement Maintenance Body Removal Procedure 1 Ensure that the headlamp switch is in the OFF position 2 Using your hands peel the rubber gasket away from the sides of the lens 3 Lift the lens 1 off the lamp assembly 4 Press down and turn the bulb counterclockwise and pull out of the socket 1693479 2005 LSSV Service Manual Supplement Body Installation Procedure Important Use the following bulbs for replacement e Park stoplamp 1157 Turn signal 1156 e Backup lamp 1156 1 Install the bulb into the socket press down and turn clockwise until fully seated Important Ensure that the lens is fully installed in the gasket The word TOP on the lens 1 must be facing up 2 Install the lens into the lens gasket License Plate Lamp Replacement LSSV Removal Procedure Important The bulb is not replaceable but is serviced as a lamp assembly 1 Ensure the headlamp switch is in the OFF position 2 Remove the bolts 1 from the lamp 3 Disconnect the electrical connector Installation Procedure 1 Connect the electrical connector Notice Refer to Fastener Notice in Cautions and Notices 2 Install the lamp and bolts 1 onto the bumper Tighten Tighten the lamp bolts to 0 8 N m 7 Ib in 2005 LSSV Service Manual Supplement Lighting Systems 8 135 1693479 1692749 1692749
163. llation must be a proper fit 2 3 Install the O ring with the lens cap 2 Install the 3 screws 1 to the assembly Marker Lamp Replacement Front Blackout B O LSSV Removal Procedure Js 2 3 Ensure all lamp switches are in the OFF position Remove the wiring harness strap 4 from the marker lamp harness Remove the harness connector 3 by releasing the connector tab Remove the nuts 1 and the ground connector 2 from the marker lamp Remove the blackout B O marker lamp assembly 1 from the bumper 2005 LSSV Service Manual Supplement Lighting Systems 8 127 1693473 1693474 1692783 8 128 Lighting Systems Body Installation Procedure 1 Install the marker lamp 1 into the front bumper opening 1692783 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 Secure the harness in the original mounting location using the wiring harness strap 4 1693474 Marker Lamp Replacement Front Blackout B O Ambulance Maintenance Body Removal Procedure 1 Ensure all lights are in the OFF position 2 Remove the wiring harness strap 4 from the marker lamp harness 3 Remove the harness connector 3 by releasing the connector tab 4 Remove
164. matic Reference Exterior Lights Schematics and Interior Lights Schematics Did you review Blackout B O Lighting Description and Operation Go to Blackout B O 1 Lighting Circuit Go to Step 2 Operation Verify that the marker lamps are always on Go to Testing for Do the marker lamps operate normally Electrical Intermittents in Wiring Systems in 2005 C K Truck Service Manual Go to Step 3 1 Disconnect the blackout B O service switch 2 Connect a test lamp between circuit 911 PK cavity A wire and ground Does the test lamp illuminate Go to Step 4 Go to Step 5 Repair a short to power in circuit 911 PK or circuit 900 BN WH wire s between the blackout B O service switch and blackout B O marker lamps Did you complete the repair Go to Step 6 Replace the blackout B O service switch Refer to Blackout B O Switch Replacement Did you complete the replacement Go to Step 6 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 DRL Operate in Blackout B O Mode Sep Actio Tes Ne Schematic Reference Exterior Lights Schematics and Interior Lights Schematics Did you review Blackout B O Lighting Description and Operation Go to Blackout B O Lighting Circuit Go to Step 2 Operation 1 Place the blackout B O service switch in blackout B O mode 2 Connect a test lamp at cavity C of the blackout B O switch and ground Does the test lamp illumi
165. mek eee ee ee e e e e e eee 3 40 Tire Pressure Monitor Sensor Replacement eee e ee ee e eee e 3 41 Tire Pressure Monitoring Sensor Programming 3 42 Learn Procedure with Initiator 3 48 Description and Operation 3 50 Tire Pressure Monitor Description and S aue RT 3 50 Initiator Programming EE EM EA 3 51 Understanding Temperature Compensated Pressure Readings 3 51 Special Tools and Equipment 3 51 3 2 Table of Contents Suspension BLANK 2005 LSSV Service Manual Supplement Suspension Front Suspension 3 3 Front Suspension Specifications Fastener Tightening Specifications Specification Application Jounce Shock Lower Bolt 92 Ib ft Jounce Shock Upper Bolt 92 Ib ft Lower Jounce Control Arm Brace Bolt 53 Ib ft Lower Jounce Control Arm Pivot Bolt 180 Ib ft 2005 LSSV Service Manual Supplement 3 4 Front Suspension 1 1700956 1 1700956 Suspension 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 2 75 in 0 15 in 7 0 cm 4 0 mm 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
166. minate Go to Step 5 Go to Step 4 Replace the blackout B O service switch Refer to Blackout B O 4 Switch Replacement Did you complete the replacement Go to Step 9 Locate and repair the short to voltage on circuit 912 OG eee Did you complete the repair Go to Step 9 Remove the backup lamp interrupt relay from the realy module uem mm E yo comper e replacement eee Did you complete the replacement Go to Step 9 Locate and repair the short to voltage on circuit 1970 PK WH ei Did you complete the repair Go to Step 9 Operate the system in order to verify the repair e l Did you correct the condition System OK Go to Step 2 2005 LSSV Service Manual Supplement Replace the blackout B O service switch Refer to Blackout B O 4 Switch Replacement Did you complete the replacement Go to Step 9 Lighting Systems 8 117 Backup Alarm Always On Schematic Reference Exterior Lights Schematics Did you perform the Diagnostic System Check Vehicle 1 Block the wheels and set the parking brake 2 Turn ON the ignition with the engine OFF 3 Place the gear selector in and out of the reverse position Does the backup alarm operate properly 1 Turn OFF the ignition switch 3 2 Disconnect the neutral start backup switch 3 Turn ON the ignition with the engine OFF Is the backup alarm on Inspect for poor connections at the harness connector of the b
167. mount Refer to Rear Jounce Shock Absorber Mount Replacement 2005 LSSV Service Manual Supplement Rear Suspension 3 9 1700962 1700962 3 10 Rear Suspension Suspension Rear Jounce Shock Absorber Mount Replacement 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 2005 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 1700961 Installation Procedure 1 Install the mount 3 and shock into position on the vehicle Notice Refer to Fastener Notice in Cautions and Notices 2 Install bolts 1 through frame and into the mount Tighten Tighten bolts to 72 N m 53 Ib ft 3 Install bolts 4 and nuts 2 into mount Tighten Tighten nuts and bolts to 72 N m 53 Ib ft 4 Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual 1700961 Shock Absorber Cover Replacement Left 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 2005 C K Truck Service Manual 2 Remove the top cover bolt 1 1700958 2005 LSSV Service Manual Supplement Suspension Rear Suspension 3 11
168. mp 1391785 1708840 Connector Part e 12015791 Connector Part e 12010996 Information e 1 Way F Weather Pack BK Information e 1 Way M Weather Pack BK Circuit Circuit Wire Color No Wire Color No Blackout B O Marker Blackout B O Marker C102M Front Blackout B O Harness to Blackout B O Headlamp 1391785 1708840 Connector Part e 12015791 Connector Part e 12010996 Information e 1 Way F Weather Pack BK Information e 1 Way M Weather Pack BK Circuit Circuit Wire Color No Wire Color No Blackout B O Headlamp Blackout B O Headlamp 2005 LSSV Service Manual Supplement Body Wiring Systems 8 169 C103M Front Blackout B O Harness to I P Harness 635009 333041 Connector Part akla Connector Part did ac s 2 Way M Weather s 2 Way F Weather i G Inf or maton Pack SHD BK A Pack TWR BK yl shea Wire Color Wire Color Blackout B O Head Lamp Blackout B O Head Lamp A TNWH Supply iae Supply tice Ei Blackout B O Marker EN BRE EI Blackout B O Marker Lamps Supply Voltage Lamps Supply Voltage C105M UBEC Harness to Relay Interrupt Harness e 12129136 Connector Part Connector Part e 12129135 e 4 Way F Flex Lock Information 280 Series BK Information e 4 Way M M P 280 Series BK Wire Color Wire Color 5 NNUNE NN Ape des a 8 ewe 1969 am Beam ay MONS nm c eke 197 Supply Voltage Beam e 2005 LSSV Service Manual Supplement 8 170 Wiring Systems Body C106M UBEC Harne
169. n Does the backup alarm operate properly 2005 C K Truck Service Manual Go to Step 3 3 Do the backup lamps operate properly Go to Backup Lamps Go to Step 4 Inoperative Inspect for poor connections at the harness connector of the backup lamp switch Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems in 2005 C K Truck Service Manual Did you find and correct the condition Go to Step 8 Go to Step 5 Test the backup alarm supply voltage circuit for a high resistance or an open Refer to Circuit Testing and Wiring Repairs in Wiring Systems in 2005 C K Truck Service Manual Did you find and correct the condition Go to Step 8 Go to Step 6 Test the backup alarm circuit for a high resistance or an open Refer to Circuit Testing and Wiring Repairs in Wiring Systems in 2005 C K Truck Service Manual Did you find and correct the condition Go to Step 8 Go to Step 7 Replace the backup alarm Refer to Backup Alarm Replacement Operate the system in order to verify the repair wee mp Did you correct the condition System OK Go to Step 2 2005 LSSV Service Manual Supplement Body Repair nstructions 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
170. nance Body Voltmeter Gage Lamp Replacement Topper Dome Lamp Replacement Topper Dome Lamp Bulb Replacement Backup Lamp Replacement Ambulance Body Backup Lamp Bulb Replacement Description and Operation Blackout B O Lighting Circuit Operation Function Tables 2005 LSSV Service Manual Supplement Table of Contents 8 3 Paint Coatings 8 144 Specifications 8 144 mise qu 8 144 Repair Instructions 8 144 Exterior Painting LSSV semer emsale 8 144 Grille Refinishing LSSV 8 144 Beats eri da ii ai Hi oor RV IU 8 145 Specifications 8 145 Fastener Tightening Specifications 8 145 Repair Instructions 8 146 Seat Replacement Troop 8 146 Description and Operation 8 146 Folding Rear Seat Troop 8 146 SeatCovels 8 146 Wiring Systems 8 147 Specifications 8 147 Fastener Tightening Specifications 8 147 Schematic and Routing Diagrams 8 147
171. nate Go to Step 3 Go to Step 6 1 Disconnect the blackout B O service switch connector from the switch 2 Connect a test lamp at cavity C of the connector and ground Does the test lamp illuminate Go to Step 5 Go to Step 4 Switch Replacement Did you complete the replacement Go to Step 9 Locate and repair the short to voltage on circuit 912 0G Did you complete the repair Go to Step 9 ENTE Remove the DRL interrupt relay from the relay module Replace the DRL relay Locate and repair the short to voltage on circuit 592 L GN Bk EUM Did you complete the repair Go to Step 9 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 mn Replace the blackout B O service switch Refer to Blackout B O 4 2005 LSSV Service Manual Supplement Body Lighting Systems 8 113 Backup Lamps Inoperative Stp ction es TN Schematic Reference Exterior Lights Schematics and Interior Lights Schematics Did you review Blackout B O Lighting Description and Operation Go to Blackout B O Lighting Circuit Go to Step 2 Operation 2 Is only one backup lamp inoperative Go to Step 3 Go to Step 4 Test the backup lamp supply voltage circuit of the inoperative bulb for high resistance an open or a short to ground Did you find and correct the condition Go to Step 17 Go to Step 5 1 Inspect the condition of the backup lamp fuses 2 If the fuse is open locate and r
172. nd temperature units Unit Combinations are PSI F Bar F Bar C psi C Programming Steps 1 Enter Level 1 Programming Mode Refer to Entering Programming Modes 2 To enter this function press the MODE button until the pressure and temperature units are displayed psi Bar C F 3 Press the TIRE button to enter 4 Use the TIRE or MODE button to scroll through the four combinations of the unit settings 1641555 2005 LSSV Service Manual Supplement Suspension 5 When the desired combination is displayed press the SET button to save and exit this mode 6 Press the SET button again to revert to normal mode 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 Press the MODE button to select it for editing 5 Use the TIRE or MODE button to adjust the value to the number determined in step 4 6 Press the SET button when the number representing the desired sensor is achieved This returns the display to the tire selection menu Scroll to a different tire location and edit the sensor numbers as above 7 Press
173. ngine Electrical in 2005 C K Truck Service Manual Is the generator operating properly Go to Step 2 Go to Step 10 1 Start the engine Verify that the noise can be heard 2 Turn OFF the engine 3 Disconnect the 4 way connector from the generator 4 Start the engine 5 Listen for the noise Has the noise stopped 1 Turn OFF the engine 2 Remove the drive belt Refer to Drive Belt Replacement in Engine Mechanical 6 6 L in 2005 C K Truck Service Manual 3 Spin the generator pulley by hand Does the generator shaft spin smoothly and without any roughness or grinding noise Go to Step 4 Inspect the generator for a loose pulley and or pulley nut Is the generator pulley or pulley nut loose Go to Step 11 Loosen all of the generator mounting bolts Tighten the generator mounting bolts to specifications and in the proper sequence if necessary Refer to 24V Generator 5 Replacement Install the drive belt Refer to Drive Belt Replacement in Engine Mechanical 6 6L in 2005 C K Truck Service Manual Start the engine Go to Step 10 Go to Step 3 Go to Step 10 Go to Step 5 system OK Go to Step 6 Inspect the generator for the following conditions e Strained or stretched electrical connections Hoses or other vehicle equipment resting on the generator which may cause the noise to be transmitted into the passenger compartment Are any electrical connections pulling on the generator or are any hose
174. nitoring system The replacement tire for the beadlock rim is a LT 285 75 R16 Goodyear Special Tools and Equipment Illustration Tool Number Description D528235 H1 Run Flat Lubricant 1700101 2005 LSSV Service Manual Supplement Suspension Tire Pressure Monitoring 3 31 Tire Pressure Monitoring Schematic and Routing Diagrams 2005 LSSV Service Manual Supplement jueuiejddng jenuey 891449S ASST 5002 Tire Pressure Monitoring System Schematics Tire Pressure Sensor LF 22 Solid State Tire Pressure Sensor RF Ez Solid State Tire Pressure Sensor RR Solid State Tire Pressure Sensor LR Solid State 243 0 5 CONN ID C1 68 GY C526 GY C9 12 BK C6 4 CM C10 12 NA C3 12 BN C726 BN C4z 6 CM C8 6 BK 243 1050 RD BK 0 5 0 5 Block I P Interior Lights Dimming Schematics in Lighting Systems S200M Tire Pressure Monitoring Receiver Receive input 9 BN 0 8 9 C201M A BN 243 0 8 RD 0 5 9 0 5 0 8 W O MNB W MNB 9 BN 0 8 A B c Tire Pressure Monitoring Gage 1698014 BUNONUONN oeuYnssaJd L ZE uoisuedsns Suspension Tire Pressure Monitoring 3 33 Component Locator Tire Pressure Monitoring System Component Views Monitoring Gage 1641375 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 Pr
175. nnector C102M cavity A of the blackout B O headlamp and ground Does the test lamp illuminate 1 Disconnect the blackout B O lamp 2 Connect a self powered test lamp at circuit 151 BK and ground Does the test lamp illuminate Locate and repair open circuit 151 BK between blackout B O Go to Step 4 Go to Step 7 headlamp and G100M Go to Step 6 Go to Step 5 Did you complete the repair Go to Step 20 a Replace blackout B O headlamp bulb a Did you complete the replacement Go to Sfep 20 1 Place blackout B O switch to ON position Go to Step 8 Go to Step 9 2 Connect a test lamp at circuit 901 TN WH wire between blackout B O drive relay cavity 85 and ground Does the test lamp illuminate Go to Step 20 NM Go to Step 10 Go to Step 11 Go to Step 13 Go to Step 15 Go to Step 12 Go to Step 14 Go to Step 20 Replace blackout B O drive relay Ss Did you complete the replacement Go to Step 20 Go to Step 19 Go to Step 18 Go to Step 16 Go to Step 17 Go to Step 20 NEN 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 Connect a test lamp at circuit 911 PK wire between blackout B O drive relay cavity 87 and ground Does the test lamp illuminate Connect test lamp at circuit 915 WH wire cavity 86 and cavity 87 of the blackout B O drive relay Does the test lamp illuminate Connect
176. ns 8 28 Center Radiator Grille Brush Guard Replacement see eee eia e ee eee 8 28 Outer Radiator Grille Brush Guard Replacement A bud rrEs 8 29 Radiator Grille Brush Guard Replacement 8 29 Center Front Bumper Replacement 8 30 Bumper Replacement Front 8 30 Bumper End Cap Replacement Front 8 34 Bracket Replacement Front Bumper 8 36 Step Pad Replacement Rear Bumper 8 37 License Plate Bracket Replacement 8 38 2005 LSSV Service Manual Supplement Bracket Replacement Rear Bumper LSSV 8 38 Bracket Replacement Rear Bumper Maintenance Body 8 40 Bumper Replacement Rear Maintenance Body 8 40 Bumper Replacement Rear LSSV 8 42 Exterior Trim erir si mii iban ili 8 46 Specifications 8 46 Fastener Tightening Specifications 8 46 Repair Instructions 8 47 Guard Mud Rear One or Both Replacement 8 47 Description and Operation 8 47 Exterior Trim Description 8 47 Frame and Underbody 8 48 Specifications 8 48 Fastener Tightening Sp
177. ns 2 6 Remove the rubber cover from the rear of the positive cable connection 7 Disconnect the positive cable connection 3 8 Remove the slave receptacle and the gasket from the bracket Installation Procedure Important The gasket must mount to the square back of the slave start connector assembly 1 Position the slave receptacle with the gasket onto the bracket 2 Install the positive cable onto the connection 8 Notice Refer to Fastener Notice in Cautions and Notices 3 Install the negative cable onto the connection 2 Tighten Tighten the connections to 20 N m 15 Ib ft 2005 LSSV Service Manual Supplement Engine 4 9 Install the rubber cover onto the rear of the positive cable connection Position the slave receptacle cover onto the rear of the bracket Install the fasteners 2 onto the slave receptacle 3 and the slave receptacle cover 1 Tighten Tighten the bolts to 8 N m 71 Ib in Install the slave receptacle cover 1 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure Slave Receptacle Replacement Ambulance Maintenance Body Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 2 3 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure Unscrew the slave receptacle cover 2 Remove the fasteners 3 securing the slave receptacle to the slave recep
178. nt 1698266 5 Remove the front winch mount Refer to Front Winch Harness and Connector Replacement in Engine Electrical 6 Remove the side bolts 1 from the inside and outside frame 7 Remove the lower washered bracket bolt 2 from the frame 8 Remove the bracket from the vehicle frame 1698263 Installation Procedure 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 Refer to Center Radiator Grille Brush Guard Replacement 1698266 2005 LSSV Service Manual Supplement Body Install the front winch mount Refer to Front Winch Harness and Connector Replacement in Engine Electrical Notice Refer to Fastener Notice in Cautions and Notices 8 Align the front bumper and tighten the side frame bolts 1 and lower frame washered bracket bolt 2 Tighten e Tighten side bolts to 128 148 N m 94 109 lb ft e Tighten lower bolt to 68 92 N m 50 68 Ib ft Step Pad Replacement Rear Bumper Removal Procedure 1 Remove the upper mounting bolts 1 2 Remove the lower mounting bolts 2 3 Remove the step from the bumper Installation P
179. nt Gun Rack Replacment 2005 LSSV Service Manual Supplement Body Floor Mount Gun Rack Replacement Removal Procedure 1 Remove the rear nut securing gun rack to the floor 2 Loosen the inner rear front seat bolts enough to slide back 3 Remove the gun rack 1 from vehicle 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 Ib ft e Tighten the front bolts to 55 N m 41 Ib ft Lower Cab Mount Gun Rack Replacment Removal Procedure 1 Remove the 2 bolts 1 holding the support to the floor 2 Remove the support 2 2005 LSSV Service Manual Supplement Interior Trim 8 83 1703189 1703189 1703190 8 84 Interior Trim 1703190 1703191 1703191 Body Installation Procedure 1 Install the support 2 by aligning the bolt holes Notice Refer to Fastener Notice in Cautions and Notices 2 Install the 2 bolts 1 holding the support to the floor and tighten Tighten Tighten the bolts to 3 5 N m 30 Ib in 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 2005 C K Truck Service Manual 2 Remo
180. o Fastener Notice in Cautions and Notices 2 Install the nuts 1 securing the brackets to the vehicle Tighten Tighten the bolt to 9 N m 80 Ib in 3 Install the vehicle jack tools in the mounts 1702786 2005 LSSV Service Manual Supplement Body Lighting Systems 8 89 Lighting Systems Specifications Fastener Tightening Specifications Specification Application English 08 Nm 08Nm Backup Lamps 0 8 N m Blackout B O Headlamp Stud Nut 10 N m Backup Alarm Bolts Backup Alarm Wiring Connector Nuts Blackout B O Switch Nuts 2 8 Nem 24 lb in Front Blackout B O Marker Lamp Nuts License Plate Lamp Bolts 15H 27 Ne Military Trailer Connector Bolts Rear Blackout B O Lamp Nuts Taillamp Bracket to Bumper Nuts M l G ho l Z Z 3 3 gt Schematic and Routing Diagrams 2005 LSSV Service Manual Supplement jueuiejddng jenuey 891449S ASST 5002 Exterior Lights Schematics Blackout B O Relay Block eee eee ee RCC A C1NZF11 B9 D3 1080 1969 1970 WH BK WH PK WH 0 8 0 8 0 8 i Park Hi Beam Low Beam Relay Relay Relay l 30 86 30 T86 30 Tse i i i s 87 85 87 0 85 87 85 i i i 1 e a ees 1970 PKAWH 0 8 B Yo B9 C1 D3 Ground Distribution Schematics in Wiring Systems G105M Existing Wiring Disconnected From Fuse Block Underhood Refer to the 2005 C K Truck Service Manual 87 V7 85 639 PK 0 8 D10 L Nel Oc Block Underhood
181. ody Install the 3 bolts and the 3 clamps onto the blackout B O harness the slave receptacle and the bumper assembly Install the blackout B O marker lamps onto the bumper Refer to Marker Lamp Replacement Front Blackout B O LSSV or Marker Lamp Replacement Front Blackout B O Ambulance Maintenance Body in Lighting Systems Install the slave receptacle onto the bumper Refer to Slave Receptacle Replacement LSSV or Slave Receptacle Replacement Ambulance Maintenance Body in Engine Electrical Install the blackout B O headlamp onto the bumper Refer to Headlamp Replacement Blackout B O LSSV or Headlamp Replacement Blackout B O Ambulance Maintenance Body in Lighting Systems Install the front winch connector Refer to Front Winch Harness and Connector Replacement in Engine Electrical Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Bumper End Cap Replacement Front Removal Procedure 1 Remove the center brush guard Refer to Center Radiator Grille Brush Guard Replacement Remove the brush guard end Refer to Outer Radiator Grille Brush Guard Replacement Remove the bolts 1 from the end cap brace If the right side is being removed the ground cable must also be removed Remove the blackout B O marker lamp Refer to Marker Lamp Replacement Front Blackout B O LSSV or Marker Lamp Replacement Front Bl
182. of G100M vehicle G101M In the 24V generator harness G103M Right side of engine block Left side of bulkhead next to the power TOAN brake booster Left side of bulkhead next to the power GAGA brake booster G301M Right outer side of frame rail G304M Under left side of I P In the rear blackout B O harness at the G901M rear of the vehicle 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 C the front blackout B O harness at front umper S200M Under steering column S201M Under steering column 202M Under steering column In the voltage regulator harness under peels the I P S304M In I P wiring harness under I P In the relay block harness next to the 3306M underhood fuse block In the relay block harness next to the SUM underhood fuse block S308M In the interrupt relay harness under the I P S309M In the interrupt relay harness under the I P S310M In the interrupt relay harness under the I P S311M In the interrupt relay harness under the I P S312M In the interrupt relay harness under the I P S313M In the I P harness under the I P In the rear blackout B O harness at rear S901M bumper In the rear blackout B O harness at rear S902M Dp 3 X 3 gt D D 5 R JJ JJ G G 3 z 5 gt gt S D 2 2005 LSSV Service Manual Supplement Body Wiring Sys
183. olored Follow the flush procedure Refer to Flushing in Engine Cooling in 2005 C K Truck Service Manual Filling Procedure Notice The procedure below must be followed Improper coolant level could result in a low or high coolant level condition causing engine damage 1 Install the lower radiator hose to the radiator 2 Using the J 38185 reposition the lower radiator hose clamp 3 If the left and right engine block coolant drain plugs were removed perform the following 3 1 Apply pipe sealer to the drain plugs Notice Refer to Fastener Notice in Cautions and Notices 3 2 Install the drain plugs Tighten Tighten the drain plugs to 60 N m 44 Ib ft 2005 LSSV Service Manual Supplement Engine Cooling 6 5 663089 635657 6 6 Engine Cooling 663089 1701828 4 s 6 T Engine Install the engine block coolant heater if equipped Refer to Coolant Heater Replacement Install the supply hose 1 at the rear of the coolant booster pump Lower the vehicle Open the cooling system bleeder screws Important Use a 50 50 mixture of DEX COOL antifreeze and clean drinkable water Slowly fill the cooling system with a 50 50 coolant mixture Refer to Capacities Approximate Fluid in Maintenance and Lubrication Close the cooling system bleeder screws Remove the return hose at the heater core of the rear HVAC and insert a funnel into the hose Add coolant until fu
184. olt 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 Ib in 6 Close the vehicle hood Verify correct fender alignment 2005 LSSV Service Manual Supplement Body Front End 8 7 1703383 1703383 8 8 Body Rear End Body Body Rear End Specifications Fastener Tightening Specifications Specification Application 9 Nem 80 Ib in 25 N m 18 Ib ft 50 N m 37 Ib ft A C Line Nut Body Ground Strap Bolt Body Mount Bolts Ambulance Body Body Mount Bolts Maintenance Body BONM SN Bm Bm 26 Nem Sm 18 Nem 0 8 Nem 58 68 N m 43 50 Ib ft 2 3 Ne oN ENM Cargo Cover Bow Strap Retaining Nuts Cargo Cover Rail Bolts Cargo Cover Rail and Hinge Upper Bolts Cargo Cover Rail Outer Bolts Cargo Cover Strut Bolts Distribution Panel Bolts Distribution Panel Shield Bolts Fiberglass Top Bolts Fuel Filler Bolts Fuel Filler Ground Wire Bolt Fuel Filler Hose Bracket Bolt 2005 LSSV Service Manual Supplement Body 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 cap 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 1703177 Installation Procedure 1 Install the new sealer tape to the bed rails
185. om the marker lamp harness 3 Disconnect the marker lamp harness connector 1 by releasing the tab 4 Remove the nuts 2 and the ground connector 3 from the rear of the bumper 1693476 2005 LSSV Service Manual Supplement Body 5 Remove the marker lamp 1 from the bumper Installation Procedure 1 Position the marker lamp 1 onto the bumper 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 marker lamp connector 4 Install the harness into the original mounting location using the wiring harness strap 2005 LSSV Service Manual Supplement Lighting Systems 8 131 1692787 1692787 1693476 8 132 Lighting Systems Body Blackout B O Taillamp Replacement Maintenance Body Removal Procedure 1 Ensure all lamp switches are in the OFF position 2 Remove the wiring harness strap from the marker lamp harness 3 Disconnect the marker lamp harness connector 1 by releasing the tab 4 Remove the nuts 2 and the ground connector 3 from the rear of the bumper 1693476 5 Remove the marker lamp 1 from the bumper 1706998 Installation Procedure 1 Position the marker lamp 1 onto the bumper 1706998 2005 LSSV Service Manual Supplement Body Lighting Systems 8 133 Notice Refer
186. onnector Replacement Maintenance Body Removal Procedure 1 Ensure that all lamp switches are in the OFF position 2 Disconnect the trailer harness connectors 1 3 Remove the fasteners securing the connector to the bumper 4 Remove the cover 3 and trailer connector 2 1706995 2005 LSSV Service Manual Supplement Body 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 Ib in 3 Connect the harness connectors 1 Headlamp Replacement Blackout B O LSSV Removal Procedure 1 Remove the nut and washer 3 from the lamp stud at the base of the mounting bracket 2 Remove the ground lead 4 by sliding it off the stud 3 Disconnect the auxiliary wiring harness connector 2 from the headlamp 4 Remove the blackout B O lamp assembly 1 from the mounting bracket Installation Procedure 1 Install the blackout B O lamp assembly 1 to the mounting bracket 2 Connect the auxiliary wiring harness connector 2 3 Install the ground lead 4 by sliding it on the stud Notice Refer to Fastener Notice in Cautions and Notices 4 Install the washer and nut 3 to the lamp stud Tig
187. ons Exterior Painting LSSV Metal Refinishing Caution Refer to Eye Protection Caution in Cautions and Notices in 2005 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 Repaint all exterior metal with lustreless paint Refer to Paint Codes for Exterior and Interior Colors Chart for current paint part number Important Exercise care when removing masking and handling vehicle after repainting to avoid marks and dirt on the new paint It is very difficult to clean up without leaving noticeable damage 4 Remove masking tape Grille Refinishing LSSV Procedure Important Ensure that all chrome areas have 10096 coverage 1 Using a coarse refinishing material scuff the surface of the grille 2 Using etching primer prepare the surface of the grille for the finish coat Important This is not CARC paint The recommended suppler is PPG 3 Repaint all exterior metal with lustreless paint Refer to Paint Codes for Exterior and Interior Colors Chart for current paint part number 2005 LSSV Service Manual Supplement Body Seats 8 145 Seats Specifications Fastener Tightening Specifications Specification Application Metric English
188. orrect Install the jounce shock absorber Refer to Jounce Shock Absorber Replacement Install the tire and wheel Refer to Tire and Wheel Removal and Installation in Tires and Wheels in 2005 C K Truck Service Manual Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual 2005 LSSV Service Manual Supplement 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 Ride characteristics are designed into the suspension system and are not adjustable A heavy duty shock absorber is used in conjunction with heavy duty hydraulic bumpers or struts to absorb dissipative energy at the end of the road wheel arm jounce travel This enhanced system will dampen out the oscillations of the torsion bar spring 2005 LSSV Service Manual Supplement Front Suspension 3 7 Front Hydraulic Jounce Bumper Description A hydraulic jounce bumper is a basic hydraulic cylinder The hydraulic jounce bumper aids the shock absorber in increased energy absorption and improved
189. ose must match the length of the old hose 1 Install the filter 1 to the hoses 2 Install hose clamps 2 and hand tighten 3 Remove the safety stands 4 Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual 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 Refer to Owner Checks and Services in Maintenance and Lubrication 2005 LSSV Service Manual Supplement Transfer Case NVG 261 NP2 4 5 1701844 1701844 4 6 Transfer Case NVG 261 NP2 Driveline Axle BLANK 2005 LSSV Service Manual Supplement Brakes Table of Contents 5 1 Section 5 Brakes Disc ge MEME PR DEM ME 5 3 Repair Instructions 5 4 Specifications eeren 5 3 Rear Brake Caliper Cover Replacement 5 4 Fastener Tightening Specifications 5 3 Rear Brake Caliper Bolt Replacement 5 5 2005 LSSV Service Manual Supplement 5 2 Table of Contents Brakes BLANK 2005 LSSV Service Manual Supplement Brakes Dis
190. oses 2 Install hose clamps 2 and hand tighten 3 Remove the safety stands 4 Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual 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 Refer to Owner Checks and Services in Maintenance and Lubrication 2005 LSSV Service Manual Supplement Driveline Axle Transfer Case NVG 261 NP2 Repair nstructions 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 2005 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 Installation Procedure Important The filter arrow must point toward the axle vent pipe If replacing the hose the length of the new h
191. ount bolts 1 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 2005 LSSV Service Manual Supplement Tires and Wheels 3 25 1698248 1698250 1698250 3 26 Tires and Wheels Suspension 3 Install the upper mount pivot bolts 1 Tighten Tighten the upper pivot mount bolts to 97 N m 72 Ib ft 4 Remove the pivot bolt and install the spare tire carrier Refer to Spare Tire Carrier Replacement In Vehicle or Spare Tire Carrier Replacement Bed Mounted or Spare Tire Carrier Replacement Swing Away 1698248 Spare Tire Carrier Latch Replacement Swing Away Removal Procedure 1 Unlatch and open the spare tire carrier swing arm 1696173 2 Remove the bolts 1 securing the latch to the bumper 3 Remove the latch from the vehicle 1696176 2005 LSSV Service Manual Supplement Suspension Tires and Wheels 3 27 Disassemble Procedure 1 Remove the latch mechanism bolts nuts and spacers 2 Remove the latch mechanism 3 Remove the latch mechanism isolator bolts 4 Remove the latch mechanism isolator 4 C LI i I Cr 5 G dc 2 ti f E J 1696178 Se
192. out B O marker lamps are mounted in the bumper of this vehicle The rear blackout B O marker lamps are arranged in the same relative position on the rear bumpers The service blackout B O lamp switches mounted at the lower center dash control blackout B O lamp and standard lamp functions A pair of toggles operates these switches The blackout B O drive toggle is mounted on the right When the service light toggle is moved up to the ON position it activates all service lights and enables all normal service light functions elsewhere to be turned ON if needed When moved to the ALL OFF position this toggle shuts off all lamps and auxiliary lamps When the switch is moved to blackout B O ON only the blackout B O lighting will work which includes the blackout B O markers front and Body rear and the blackout B O headlamp Within the rear marker lamps are separate color markers Yellow will illuminate for the brakes and red will illuminate for drive mode The front markers illuminate in yellow The horn is inoperative while the blackout B O toggle is in the ON position All warning lamps in the I P remain functional regardless of the toggle position If the vehicle is parked for over 24 hours place the service switch in the ALL OFF position 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 servic
193. ove 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 Ensure that the air fitting is in line with one of the grooves 2005 LSSV Service Manual Supplement Suspension 10 With the inner wheel studs facing up install the wheel nuts by hand to a minimum of 4 threads Notice Refer to Fastener Notice in Cautions and Notices Important The specified torgue pattern must be followed to prevent damage or improper sealing Important Retorque wheel nuts in a star pattern at 80 161 KH 50 100 MI and 8047 KH 5 000 MI thereafter retorgue to 102 108 N m 75 80 Ib ft 11 Using the torque pattern tighten the nuts Tighten e Tighten the wheel nuts first pass to 81 N m 60 Ib ft Tighten the wheel nuts second pass to 102 108 N m 75 80 lb ft Caution Allowing pressure to continue to build up within a tire in an attempt to seat the bead is a dangerous practice that can result in a broken tire bead and possible serious injury to the technician 12 Place the tire in an approved inflation safety cage and inflate to 30 psi 206 kPa 13 Check the tire bead seating for soace between the wheel flange and the tire While the wheel is lying flat inspect the entire circumference of the wheel flange If this condition exists disassemble and restart by inspecting the O ring 14 Inflat
194. ovide 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 Install the cover to the front rear and sides in the hooks and pull strap at the base of the cover as needed Cargo Cover Stowage Replacement 1 Release the front and rear support straps 2 From the rear of the vehicle push the bows and canvas forward folding the canvas around the bows Important The cover may also be folded neatly and stored behind the seat in the cab 3 Completely fold the bows down against the front of the cargo box and secure them with the front straps 2005 LSSV Service Manual Supplement Body Rear End 8 15 1701839 1701839 1701840 8 16 Body Rear End a tena LLL TT Eum IR MANN as anan ASMAMAK d AYA e M EISE gets b y HUOT gata ge 1701826 1701835 Body Body Replacement Ambulance Body Tools Required J 39400 A Halogen Leak Detector 1 Recover the refrigerant Refer to Refrigerant Recovery and Recharging in Heating Ventilation and Air Conditioning of the 2005 C K Truck Service Manual 2 Drain the cooling system Refer to Draining and Filling Cooling System Ambulance Body in Engine Cooling Caution Refer to B
195. p 12 d YUA coin sents Did the test lamp illuminate Go to Step 16 Go to Step 14 Repair the generator field circuit for an open or high resistance Did you complete the repair Replace the generator Refer to 24V Generator Replacement 4 Repair the 24V relay control voltage circuit for an open or 13 high resistance Did you complete the repair Go to Step 17 Connect a test lamp between terminal 87 of the 24V relay 14 and ground Did the test lamp illuminate Go to Step 15 Go to Step 13 Replace the 24V relay Refer to Relay Replacement 24V Go to Step 17 Generator Did you complete the replacement System OK Go to Step 2 Repair the 24V relay ground control circuit for an open or high resistance Did you complete the repair Operate the system in order to verify the repair Did you correct the condition 2005 LSSV Service Manual Supplement 6 28 Engine Electrical 1703361 1703361 Engine Repair Instructions Circuit Breaker Replacement 12V or 24V 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 nuts holding the wires to the circuit breaker and remove the wires Note the location of wires for reassembly 3 Remove the 4 screws 1 holding the 24V 2 or 12V 3 circuit breaker to the fender support 4 Remove the 24V 2 or 12V 3 circuit
196. p Description The voltmeter lamp provides illumination to the voltmeter mounted in the accessory instrument panel 2005 LSSV Service Manual Supplement Body Lighting Systems 8 143 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 Exterior Lights Marker Lamps Roof Fender and OFF OFF OFF OFF Stoplamps SERVICE ON OFF Backup Lamps SERVICE ON OFF License Plate Lamp SERVICE ON OFF Front Rear Turn Signals SERVICE ON OFF Hazard Warning Lamps ALL POSITIONS ON OFF Cargo Lamp SERVICE ON Horn SERVICE ON N Front Rear Blackout B O Marker Lamps BLACKOUT ON OFF Blackout B O Stoplamps BLACKOUT ON OFF Blackout B O Drive Lamp Headlamp BLACKOUT Interior Lights OFF OFF OFF FF Glove Compartment Lamp SERVICE ON OFF Underhood Lamp SERVICE ON OFF Warning Chime Headlamps On Safety Belt and Key in Ignition SERVICE ON ON OFF Tire Pressure Monitoring Gage Illumination SERVICE ON EM RE ALL POSITIONS ON OFF 2005 LSSV Service Manual Supplement 8 144 Paint Coatings Paint Coatings Specifications Paint Codes Body Exterior and Interior Colors Location Color Fed std 595 B 34094 CA 8211 15086 BDesetTa 8211 107086MPY228 For specific paint coating details contact PPG Automotive Coatings at 1 818 549 7979 Repair Instructi
197. p harness connectors to the blackout B O marker lamp conneciors 1 4 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Lamp Harness Replacement Rear Maintenance Body 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 Disconnect the 2 24V trailer harness connectors 5 from the 24V trailer connector harness Disconnect the 3 blackout B O and trailer harness connectors 2 Disconnect the 2 blackout B O marker lamp connectors 1 from the blackout B O marker lamps Remove the 2 bolts 3 and 2 clamps 4 from the blackout B O and the trailer harness Remove the blackout B O and the trailer harness from the bumper assembly 2005 LSSV Service Manual Supplement Wiring Systems 8 183 1703206 1704993 8 184 Wiring Systems Body Installation Procedure 1 Position the blackout B O and the trailer harness onto the bumper in the same routing location as removed 2 Install the 2 clamps 4 and the 2 bolts 3 to the blackout B O and trailer harness 3 Connect the 2 blackout B O marker lamp connectors 1 to the blackout B O marker lamps 4 Connect the 3 blackout B O and the trailer harness connectors 2 5 Connect the 2 24V trailer harness connector
198. placement Rear Maintenance Body in Wiring Systems 13 Remove the bolts 1 securing the bumper to the vehicle 14 Remove the bumper and spacers from the mounting brackets 1698274 2005 LSSV Service Manual Supplement 8 44 Bumpers Body Installation Procedure 1 Position the bumper and spacers to the vehicle and loosely install the bolts 1 Notice Refer to Fastener Notice in Cautions and Notices 2 Align the bumper from side to side and tighten bolts Tighten Tighten bumper bolts to 97 N m 72 Ib ft 3 Install the rear lamp wiring harness Refer to Lamp Harness Replacement Rear LSSV or Lamp Harness Replacement Rear Maintenance Body in Wiring Systems 4 Install the rear relay mounting bracket from the bumper 1698274 5 Install the rear winch power disconnect 2 if equipped Refer to Rear Winch Harness and Connector Replacement LSSV or Rear Winch Harness and Connector Replacement Maintenance Body in Engine Electrical 6 Install the 12V trailer connector 1 Refer to Commercial Trailer Connector Replacement LSSV or Commercial Trailer Connector Replacement Maintenance Body in Lighting Systems 7 Install the 24V trailer connector 3 Refer to Military Trailer Connector Replacement LSSV or Military Trailer Connector Replacement Maintenance Body in Lighting Systems 1698270 2005 LSSV Service Manual Supplement Body Bumpers 8 45 8 Install the license plate brack
199. plate 4 Remove the skid plate 2 from the vehicle 2005 LSSV Service Manual Supplement Body 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 Ib ft 3 Install the front bolts 1 Tighten Tighten the bolts to 20 N m 15 Ib ft 4 Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual Rear Skid Plate 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 2005 C K Truck Service Manual 2 Support the skid plate and remove the bolts 2 3 Remove the support and remove the skid plate 1 Installation Procedure 1 Install the skid plate 1 Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts 2 and remove support Tighten Tighten the bolts to 35 N m 26 Ib ft 3 Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual 2005 LSSV Service Manual Supplement Frame and Underbody 8 57 1700619 1700618 1700618 8 58 Frame and Underbody Body Front Support Beam Replacement Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices 1
200. ptacle gt 150 BK 32 77 G102M 1704604 Apog LGl g suiejs s Bui jueuiejddng jenuey 8914495 ASST 5002 Ground Distribution Schematics G105M 9c vve e m e e e e Blackout Lighting 4 Horn 0URL Low High Park Tum Relay i Relay i Relay Beam i Beam i Relay i Signal T Center i i i i i Relay i Relay i i i Relay i M m _ d M e _ m d M e m d M e m d M e d a d I a is JR ye o ye Lae e B1 Tu pe Is Tos Tu 150 150 150 150 150 BK BK BK BK BK 0 8 0 8 0 8 0 8 0 8 150 BK 0 8 G105M 1704608 suiegjs s DuuIM ZSL 8 U O Q lt jueuiejddng enuey 891449 ASST 5002 Lamp Relay 86 150 BK 0 8 1 Backup Ground Distribution Schematics G304M 77 CTSY 2 1 CTSY 1 Relay l ME 86 86 150 150 BK BK 0 8 0 8 Relay 86 150 BK 0 8 1 Dimming 1 Relay 1 Blackout i 1 Drive Lamp l 1 Switch tI T 1704607 Apog G1 g suiejs s uM jueuiejddng jenuey 891449S ASST 5002 C900M i Trailer 1 Connector 1 License Plate Lamp I A 150 BK 1 Ground Distribution Schematics G901M C908M 150 BK J e eke 86 86 150 150 BK BK 150 BK S903M 19 BK 150 0 8 S905M 150 BK G901M dT Park Lighting Systems in the 2005 C K Truck Service Manual C906M 1750 B
201. r swing arm 2005 LSSV Service Manual Supplement Tires and Wheels 3 23 1698279 1696173 3 24 Tires and Wheels 1696175 1696175 1696173 Suspension 4 Remove the nut 2 from the pivot bolt Note location of any shims or washers before removing the pivot bolt 5 Hold the carrier and remove the pivot bolt 1 6 Remove the carrier from the mount Installation Procedure 1 Install the carrier into the bracket 2 Install any shims are 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 Install the wheel nuts onto the studs Tighten Tighten the wheel nuts to 50 N m 37 Ib ft 7 Adjust the carrier latch Refer to Spare Tire Carrier Latch Adjustment Swing Away 8 Close and ensure that the spare tire carrier is latched 2005 LSSV Service Manual Supplement Suspension Spare Tire Carrier Pivot Bracket Replacement Swing Away Removal Procedure 1 Remove the spare tire carrier Refer to Spare Tire Carrier Replacement In Vehicle or Spare Tire Carrier Replacement Bed Mounted or Spare Tire Carrier Replacement Swing Away 2 Remove the top pivot m
202. r bezel out at the portion covering the panel 1694848 5 Remove panel enough to gain access to the air line 2 6 Remove the air line 2 from the flow gage 1 1693472 7 Remove the airflow line grommet 1 from the bulkhead and remove line 2 from the vehicle 1694860 2005 LSSV Service Manual Supplement 8 76 Instrument Panel Gages and Console Body Installation Procedure 1 Install the air line 2 with the grommet 1 and secure the grommet into the bulkhead opening 1694860 2 Route the air line through the I P in the same location as removed 3 Install the air line 2 onto the gage 1 1693472 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 Ib in 5 Push the I P cluster bezel back in place over the panel 1694848 2005 LSSV Service Manual Supplement Body 6 Route the air line 2 through the engine compartment as removed 7 Secure line using the clip 1 8 Push the line 2 onto the tube adapter 3 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
203. r vehicle and the bad grounding could damage the electrical systems To avoid the possibility of the vehicles rolling set the parking brake firmly on both vehicles involved in the jump start procedure Put the automatic transmission in PARK P Be sure the transfer case is not in NEUTRAL N 2 Turn OFF the ignition on both vehicles Unplug unnecessary accessories plugged into the cigarette lighter or accessory power outlets Turn OFF all lamps that are not needed as well as radios This will avoid sparks and help save both batteries 3 Locate the slave receptacles on both vehicles and unscrew the covers Engine 1703360 Caution Using an open flame near a battery can cause battery gas to explode People have been hurt doing this and some have been blinded Use a flashlight if you need more light Be sure the batteries have enough water You do not need to add water to the Optima battery or batteries installed in the vehicle But if a battery has filler caps be sure the right amount of fluid is there If it is low add water to take care of that first If you do not explosive gas could be present Battery fluid contains acid that can burn you Do not get it on you If you accidentally get it in your 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
204. rake caliper bolts to the caliper bracket DO NOT tighten 2005 LSSV Service Manual Supplement Brakes 2 3 Install the caliper and caliper bracket 1 as an assembly Perform the following procedure before installing the caliper bracket bolts e Remove all traces of the original adhesive patch Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry e 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 Tighten Tighten the bolts to 300 N m 221 Ib ft Tighten the brake caliper bolts 2 Tighten Tighten the bolts to 108 N m 80 Ib ft Install the rear brake caliper cover Refer to Rear Brake Caliper Cover Replacement Install the tire and wheel assembly Refer to Tire and Wheel Removal and Installation in Tires and Wheels in the 2005 C K Truck Service Manual With the engine OFF gradually apply the brake pedal to approximately 2 3 of its travel distance Slowly release the brake pedal Wait 15 seconds and then repeat steps 8 9 until a firm pedal is obtained This will properly seat the brake caliper pistons and brake pads Fill the master cylinder reservoir to the proper level with clean brake fluid if necessary Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes in the 2005 C K Truck Service M
205. re 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 negative cable from the engine block 3 Remove the positive cable 1 from the junction block 2 1707377 4 Remove the wiring harness straps securing the cable 5 Remove the bolt 2 securing cable connector to the bracket 6 Remove the cable 3 from the vehicle Note cable routing for installation 1707416 Installation Procedure 1 Install the cable 3 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 2 Tighten Tighten the connector bolt to 10 15 N m 7 11 Ib ft 3 Working from the rear to the front of the vehicle install the wiring harness straps 1707416 2005 LSSV Service Manual Supplement Engine 4 Install the positive cable 1 to the junction block 2 Tighten Tighten the junction block nut to 9 N m 80 Ib in Install the negative cable to the engine block Tighten Tighten the negative cable bolt to 34 N m 25 lb ft 6 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure Slave Receptacle Harness Replacement Ambulance Maintenance Body Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Noti
206. ring mounting bracket bolts 1 3 Remove the D ring bracket 2005 LSSV Service Manual Supplement Body 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 bracket mounting bolts Tighten Tighten the bolts to 87 97 N m 64 72 Ib ft 3 Install the D ring Refer to Front D Ring Replacement Ambulance Maintenance Body or Front D Ring Replacement LSSV Rear D Ring Bracket Replacement Maintenance Body Removal Procedure 1 Remove the rear bumper Refer to Bumper Replacement Rear Maintenance Body or Bumper Replacement Rear LSSV in Bumpers 2 Remove the D ring bracket crossmember Refer to D Ring Bracket Crossmember Replacement Maintenance Body 3 Remove the upper frame bolts securing the bracket to the frame 4 Remove the side bolts 3 and remove the spacer 2 and bracket 1 from the vehicle Installation Procedure 1 Install the bracket 1 spacer 2 and the side bolts 3 Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts Tighten Tighten side bolts to 120 N m 89 Ib ft 3 Install the upper frame bolts Tighten Tighten upper bolts to 90 N m 66 lb ft 4 Install the D ring bracket crossmember Refer to D Ring Bracket Crossmember Replacement Maintenance Body 5 Install the rear bumper Refer to Bumper Replacement Rear Maintenance Body or Bumper Repla
207. rmation and Procedures 8 106 Symptoms Lighting Systems 8 106 Blackout B O Headlamp lnoperative 8 107 Blackout B O Headlamp Always On 8 108 Headlamps Operate in Blackout B O VIC GE 8 108 Blackout B O Stoplamps Inoperative 8 109 INTHOGUICUION E 8 110 Blackout B O Marker Lamps Igiejo iih a m I 8 110 Diagnostic Information and Procedures 8 111 Voltmeter Gage Lamp Inoperative 8 111 Blackout B O Marker Lamps Always Oll a e kl ee lag MUN TS 8 112 DRL Operate in Blackout B O Mode 8 112 Backup Lamps Inoperative 8 113 Backup Lamps Operate in Blackout B O Mode tice e 8 114 Park Lamps Operate in Blackout B O Gela 8 114 CTSY Lamps Operate in Blackout B O Mode NANE AM AN 8 115 Turn Signals Operate in Blackout B O Mode ME PR A 8 115 Hi Beam Headlamps Operate in Blackout B O Mode kayisi amiri sise 8 116 Low Beam Headlamps Operate in Blackout B O Mode eminsen 8 116 Backup Alarm Always On 8 117 Backup Alarm Inoperative 8 118 Repair Instructions 8 119 Topper Dome Lamp Switch Replacement Front 8 119 Topper Dome Lamp Switch Replacement Rear 8 120 Blackout B O Switch Replacement 8 120 Backup Alarm Replacem
208. rocedure 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 Ib ft 3 Install the lower mounting bolts 2 Tighten Tighten lower bolts to 45 N m 33 Ib ft 2005 LSSV Service Manual Supplement Bumpers 8 37 1698263 1698267 1698267 8 38 Bumpers Body License Plate Bracket Replacement Removal Procedure 1 Remove the retention pin 1 and pivot the bracket down 2 Remove the pivot bolt 2 and washer from the bracket 3 Remove the bracket from the bumper 4 Remove the license plate from the bracket 1702051 Installation Procedure 1 Inspect the bracket pivot bushing and replace as needed 2 Install the license plate on the bracket 3 Install the bracket on the bumper and install washer and bolt 2 Tighten the bolt until the bracket pivots open freely 4 Pivot the bracket into the up position and install the retention pin 1 1702051 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 2005 C K Truck Service Manual 2 Remove the rear D ring 2 from the appropriate side Refer to Rear D Ring Bracket Replacement
209. rom the bolt and wiring mounting area 3 Install the ground wire bolt 1 for the fuel filler hose Tighten Tighten the ground wire bolt to 9 N m 80 Ib in 2005 LSSV Service Manual Supplement Body Body Rear End 8 25 4 Remove the fuel fill hose bracket bolt 1 Tighten Tighten the bracket bolt to 8 N m 71 Ib in 1701836 5 Install the fuel tank filler housing to fuel tank fill pipe bolts 1 Tighten Tighten the fuel filler bolts to 2 3 N m 20 Ib in 6 Connect the wiring harness for the maintenance body 7 Lower the vehicle 8 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 1701829 2005 LSSV Service Manual Supplement 8 26 Body Rear End Description and Operation Body Rear End Description These vehicles are eguipped with several options including a cargo cover troop seats left and right fiberglass top ambulance body and maintenance body Cargo Cover The cargo cover is a rain resistant canvas 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 Cargo Cover Cleaning If the cargo cover has deteriorated replace it The cargo cover is a waterproof welded plastic coated polyester Wash the cover using only mild soap and water Do not use cleaning agents
210. rvice 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 1696179 3 Check for operation and apply Teflon dry lube GM P N 12371287 Canadian P N 10953437 to the latch mechanism 1 as required 1504091 2005 LSSV Service Manual Supplement 3 28 Tires and Wheels Suspension Assembly Procedure 1 Install the latch mechanism isolator if necessary Notice Refer to Fastener Notice in Cautions and Notices 2 Install the latch mechanism isolator screws g Tighten Crime Nez Tighten the screws to 9 N m 80 Ib in 3 Install the latch mechanism if necessary 4 Install the latch mechanism bolts spacers and nuts Tighten Tighten the bolts to 25 N m 18 lb ft 1696178 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 1696176 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 1696176 2005 LSSV Service Manual Supplement Suspension 3 Insert a shim 1 bet
211. ry Description and Operation 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 e Always shield your eyes Avoid leaning over the battery whenever possible 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 The engine electrical options include the slave receptacle 24V generator and a three battery power system The two batteries in series provide 24V of power The 24V battery is located in the left front of the engine compartment This will provide greater power for the higher load used by optional radio communications or for compatibility with other slave receptacles on similarly equipped vehicles The LSSV vehicles are equipped with Optima batteries The Optima battery is a sealed zero maintenance battery Periodically inspect your battery terminal connections to ensure they are clean tighten to the specified torque and protected from the elements The Optima battery require a special charging procedure When charged properly you will not have to worry about leaking corrosion or gassing Refer to Battery Charging Optima procedur
212. s 5 to the 24V trailer harness 6 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 1704993 Blackout B O Lamp Wiring Harness Front Ambulance Maintenance Body 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 Disconnect the blackout B O headlamp connectors 1 from the blackout B O headlamp 3 Disconnect the blackout B O marker lamp connectors 2 from the blackout B O marker lamp 4 Trace the blackout B O lamp harness connector 3 to the main harness connector Disconnect the blackout B O lamp harness connector 3 to the main harness connecior 6 Remove the wiring harness from the vehicle Note wiring harness routing for installation 1704995 5 2005 LSSV Service Manual Supplement Body Installation Procedure 1 Position the blackout B O lamp wiring harness onto the vehicle in the same routing location as removed 2 Connect the blackout B O lamp harness connector 3 to the main harness connector 3 Connect the blackout B O marker lamp connectors 2 to the blackout B O marker lamps 4 Connect the blackout B O headlamp connectors 1 to the blackout B O headlamp 5 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine El
213. s etc resting on the generator Go to Step 7 Go to Step 8 1 Reroute the electrical connections to relieve the tension 2 Reroute the hoses etc away from the generator 3 Start the engine Has the noise decreased or stopped EMEN System OK Go to Step 8 2005 LSSV Service Manual Supplement 6 26 Engine Electrical Engine 24V Generator Noise Diagnosis cont d Yes Inspect the drive belt for proper tension Refer to Drive Belt Tensioner Diagnosis in Engine Mechanical 6 6 L in 2005 C K Truck Service Manual Is the drive belt loose Go to Step 9 Go to Step 10 1 Replace the drive belt tensioner Refer to Drive Belt Tensioner Replacement in Engine Mechanical 6 6L in 2005 C K Truck Service Manual 2 Start the engine Has the noise decreased or stopped System OK Go to Step 11 10 Compare the vehicle with a known good vehicle Do both vehicles make the same noise System OK Go to Step 11 Important f no definite generator problems were found be sure that all other possible sources of objectionable noise are eliminated before replacing the generator Replacing the generator may not change the noise level if the noise is a normal characteristic of the generator or the generator mounting Replace the generator Refer to 24V Generator Replacement Has the noise decreased or stopped Go to Step 12 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 24V Genera
214. s Lighting Systems amp ipiMarker amc EB In the left side of the rear bumper Component Views in Connector End Views P P Lighting Systems in Lighting Systems Blackout B O Lighting Systems Lighting Systems Soner Lamb BB In the right side of the rear bumper Component Views in Connector End Views p P Lighting Systems in Lighting Systems Engine Electrical Lighting Systems Mot Reda Ub neste e pane oie genter lower Component Views in Connector End Views x gag Engine Electrical in Lighting Systems Outside of frame rail under Battery 12V At the right rear engine compartment pe Battery 24V At the left front of the engine compartment Pe In the engine compartment on the left fender brace Ambulance Engine Electrical Component Views in Engine Electrical Circuit Breaker 12V Engine Electrical Component Views in Engine Electrical CTSY 1 and 2 Relay d 2 the interrupt harness under EE DRL Interrupt Relay Interrupt relay block RH engine b EUER compartment Lighting Systems Generator 24V The right front of engine Engine Electrical Generator Relay 24V On the cover of the underhood fuse block Connector End Views in Engine Electrical Gener Yi In the engine compartment inline with the EU EQUO 24V generator harness Headlamp Hi and Low Interrupt relay block RH engine e Beam Interrupt Relay compartment LE Electrical In the engine compartment on the left Circuit Breaker 24V fender brace Ambulance in
215. shings 1 to the inside and 1 to the outside of the base hole of each side strut 2 Install the front strut 85 72 cm 33 75 in inside the base of the hinge bracket at the first hole Use a nylock nut on the inboard side and a bolt on the outboard side of the bracket 3 Install the center strut 57 15 cm 22 5 in inside the bracket at the mid level hole with a nylock and bolt in similar fashion Notice Refer to Fastener Notice in Cautions and Notices 4 Install the rear strut 82 14 cm 32 34 in at the top hole with the nylock and bolt in similar fashion Tighten Tighten the strut bolt to 5 N m 44 Ib in 5 Install the cargo cover and top bows Refer to Cargo Cover Top Bows Replacement and Cargo Cover Strut Replacement 2005 LSSV Service Manual Supplement Body Rear End 8 13 1703181 1703182 1703182 8 14 Body Rear End 1703184 1703184 Body Cargo Cover Top Bows Replacement Removal Procedure 1 Remove the cargo cover Refer to Cargo Cover Replacement 2 Remove the strap tensioners from the front and rear top bows by withdrawing from the side rail loop 3 Remove the 6 pins 1 holding the 3 top bows to the 6 side struts 4 Remove the 3 top bows from the struts 5 Slide the strap off each top bow Remove the bows from the vehicle 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
216. sive acid Batteries supply levels of electrical current high enough to Jump Starting in Case of Emergency 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 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 1703359 If the battery or batteries on the vehicle has run down and the vehicle will not start you may want to use another vehicle to provide power to start the vehicle The NATO term for this system is slave start receptacle 1 In the event the system must be replaced refer to Slave Receptacle Replacement LSSV or Slave Receptacle Replacement Ambulance Maintenance Body NATO Slave Cables are the only recommended method of jump starting similar vehicles 2005 LSSV Service Manual Supplement 6 24 Engine Electrical SON DON ANNUI mn NS ROS 1703359 1 Position the vehicles close enough so the slave cable can reach but be sure the vehicles are not touching each other If they are it could cause a ground connection You would not be able to start you
217. ss the SET button to exit 8 Press the SET button again to revert to normal view Low Pressure Warning Important This function changes to low pressure warning threshold for each axle For tire pressure setting specifications refer to Tire Inflation Pressure Specifications in Maintenance and Lubrication Factory default 18 psi 1 24 Bar 1 Enter Level 1 Programming Mode Refer to Entering Programming Modes 2 To enter this function press the MODE button until the flat tire icon and pressure units are displayed 3 Press the TIRE button to scroll to the desired axle The tires of the selected axle are filled in 2005 LSSV Service Manual Supplement Suspension oo 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 9 Press the SET button to exit Press the SET button again to revert to normal view Pressure Deviation Alert Important This function sets the pressure deviation alert threshold for all tires Factory Default 5 psi 34 Bar i 2 Enter Level 1 Programming Mode Refer to Entering Programming Modes To enter this function press the MODE button until the icon and pressure units are displayed Press the TIRE button to s
218. ss to Relay Interrupt Harness e 12129489 Connector Part Connector Part e 12129490 Information 3 Way F MP Flex Lock Information 3 Way M P 280 Series BK 280 Series BK Pn wire cotor Sno Funeton pim wre cotor nos aaa Wire Color No Wire Color No e oken 1329 Horn Supply votas 8 Den 1929 Hom Supply Voltage 04 04 Radio Supply Voltage Radio Supply Voltage C107M I P Harness to Relay Block Harness 1391785 1708840 Connector Part 12015791 Connector Part 12010996 Information 1 Way F Weather Pack BK Information e 1 Way M Weather Pack BK Circuit Circuit Wire Color No Wire Color No Supply Voltage Supply Voltage to Relay Module a di 912 to Relay Module 2005 LSSV Service Manual Supplement Body Wiring Systems 8 171 C108M I P Harness to Rear Lamp Extension Harness 283957 Connector Part e 12103784 Connector Part e 12034014 Information 2 Way F Weather Pack GY Information 2 Way M Weather Pack GY Circuit Circuit Wire Color No Wire Color No Hear Marker Hear Marker Rear Stoplamp Rear Stoplamp C201M I P Harness to Tire Pressure Monitoring System Harness 1391785 1708840 Connector Part 12015791 Connector Part 12010996 Information 1 Way F Weather Pack BK Information e 1 Way M Weather Pack BK Circuit Circuit Wire Color No Wire Color No A BN Supply Voltage to TPMS A BN Supply Voltage to TPMS Gage Dimming Gage Dimming 2005 LSSV Service Manual Supp
219. t Maintenance Body in Frame and Underbody Remove the body mount nut 1 Remove the bumper bolts 2 Remove the frame bolts 3 and remove the bracket from the vehicle C1 BW Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 1 Place the bracket on the vehicle and install the frame bolts 3 Tighten Tighten frame bolts to 120 N m 89 Ib ft 2 Install the body mount bolt 1 Tighten Tighten body mount bolts to 80 N m 59 Ib ft 3 Install the bumper bolts 2 Tighten Tighten bumper bolts to 50 N m 37 Ib ft 4 Install the rear hitch and reinforcement plate Refer to Trailer Hitch Reinforcement Plate Replacement Maintenance Body in Frame and Underbody 5 Remove the safety stands and lower the vehicle Bumper Replacement Rear Maintenance Body 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 D rings Refer to Rear D Ring Replacement Maintenance Body or Rear D Ring Replacement LSSV in Frame and Underbody 3 Disconnect the trailer wiring harness 4 Remove the 4 bumper bolts 1 right side shown left side similar 5 Using the aid of an assistant remove the rear bumper from the vehicle by sliding it off the brackets 2005 LSSV Service Manual Supplement Body Bumpers 8 41 6 Remove the
220. t li at any time you are uncertain that the Actual side and this should be pushed upward to turn the Pressure reading on the display indicates the correct T ON and downward A tire pressure switch to the Pressure Deviation initiator OFF readout A blank display indicates that the reading on the display is the correct one Any or value indicates the tire pressure is incorrect by that value Understanding Temperature This value can then be used to correctly inflate the tire Compensated Pressure Readings An important feature of the SmarTire Full Function Special Tools and Equipment Display system is that pressure deviation alerts are illustration Tool Number Description initiated from a comparison of the temperature compensated pressure to the measured tire pressure read by the sensor LF INITIATOR The reference pressure or COLD PRESSURE is the Rec ATE air pressure inside the tire inflated at room temperature CO eeuenoize 18 C 64 F to the vehicle manufacturer s m 090 0006 recommendation When a tire heats up the air pressure Programming Initiator inside the tire can also be expected to increase For example a normal or required pressure at 64 F or 18 C may be 34 psi 2 35 Bar and a normal pressure at 49 C 120 F may be 39 psi 2 7 Bar Both pressure readings are correct at their respective temperatures 2005 LSSV Service Manual Supplement 3 52 Tire Pressure Monitoring Suspension BL
221. t of the inoperative lamp for high resistance an open or a short to ground Refer to Circuit Testing and Wiring Repairs in Wiring Systems in 2005 C K Truck Service Manual Did you find and correct the condition Go to Step 10 Go to Step 7 Go to Step 15 Go to Step 9 Test the ground circuit of the inoperative lamp for high resistance or an open Refer to Circuit Testing and Wiring Repairs in Wiring Systems in 2005 C K Truck Service Manual Did you find and correct the condition Go to Step 15 Go to Step 14 Using a fused jumper connect cavity D to cavity F of the blackout B O service lamp switch connector Do the brake lamps illuminate Replace blackout B O service lamp switch Refer to Blackout B O Switch Replacement Did you complete the replacement Connect a test lamp between terminal A of the rear blackout B O stoplamps and ground Did the test lamp illuminate Go to Step 14 Locate and repair the open or high resistance in circuit 902 Did you correct the condition Go to Step 15 Replace the blackout B O stoplamp s Refer to Taillamp Blackout B O Lamp Replacement e Go to Step 11 Go to Step 12 Go to Step 15 NO Go to Step 13 Did you complete the replacement Operate the system in order to verify the repair Did you correct the condition system OK Go to Step 15 Go to Step 2 2005 LSSV Service Manual Supplement 8 110 Lighting
222. t to the interior of the ambulance body The HVAC control panel is located on the front interior wall of the ambulance body and controls HVAC operation Placing the HVAC switch in the OFF position turns on the solenoid closing the water valve This action will not allow coolant to flow through the booster pump or auxiliary heater core The location of the water valve is under the vehicle on the right outer frame rail When heat is desired the HVAC switch is in the ON position and the valve is opened Coolant will then flow to the booster pump The booster pump electrically pumps the coolant though the heater core of the rear HVAC module The booster pump is located under the vehicle on the right outer frame rail 2005 LSSV Service Manual Supplement Steering Table of Contents 2 1 Section 2 Steering Power Steering System 2 3 Repair Instructions 2 4 Specifications sarsam simental etre Eck 2 3 Power Steering Pump Heat Shield Fastener Tightening Specifications 2 3 Replacement RTT 2 4 2005 LSSV Service Manual Supplement 2 2 Table of Contents Steering BLANK 2005 LSSV Service Manual Supplement Steering Power Steering System 2 3 Power Steering System Specifications Fastener Tightening Specifications Specification Application Metric English Power Steering Pump Heat Shield Bolts 8 N m 71 Ib in 2005 LSSV Service Manual
223. tacle and connect the rear connector cover 1 Remove the slave receptacle cover 2 Disconnect the negative cable connections 2 Remove the rubber cover from the rear of the positive cable connection Disconnect the positive cable connection 3 Remove the slave receptacle and the gasket from the bracket 2005 LSSV Service Manual Supplement Engine Electrical 6 47 1706968 1706662 1706663 6 48 Engine Electrical 1706663 1706662 Engine Installation Procedure Important The gasket must mount to the square back of the slave start connector assembly 1 Position the slave receptacle with the gasket onto the bracket 2 Install the positive cable onto the connection 8 Notice Refer to Fastener Notice in Cautions and Notices 3 Install the negative cable onto the connection 2 Tighten Tighten the connections to 20 N m 15 Ib ft Install the rubber cover onto the rear of the positive cable connection Position the slave receptacle cover 1 onto the rear of the bracket Install the fasteners 3 onto the slave receptacle and through the slave receptacle rear connector cover Tighten Tighten the bolts to 8 N m 71 Ib in Install the slave receptacle cover 2 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure 2005 LSSV Service Manual Supplement Engine Description and Operation Batte
224. te is located on the left front inner door panel above the vehicle identification plate This plate includes the loading and dimensions 2005 LSSV Service Manual Supplement General Information Maintenance and Lubrication 0 7 Maintenance and Lubrication Specifications Capacities Approximate Fluid See Fluid and Lubricant Recommendations for more information All capacities are approximate When adding be sure to fill to the approximate level as recommended in this manual Recheck fluid level after filling Capacities Approximate Fluid Specification Application Metric Cooling System Fluid and Lubricant Tire Inflation Pressure Recommendations Specifications 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 Important These pressures and specifications are for Enhanced Mobility Package EMP or RPO EM7 only Tire Inflation Pressure Specifications EMP Only Terrain Deflection Maximum Speed Load Minimum Inflation Highway FrntAde 89 mph 149 kmn 2400 Ibs 1089 gj 45 PSI 10 Bar Highway Rear Axe 98 mph 149 kmh 3042 1bs 1390ko 65 PSI 4 48 Bar i 20 PSI 276 Bar Highway 18 Cross Country 30 mph 48 km h 2300 Ibs 1043 kg 23 PSI 1 59 Bar Mud Sand Snow 10 mph 16 km h 2300 Ibs 1043 kg 18 PSI 1
225. tems 8 163 Master Electrical Component List cont d Neme Location Locator View Connector End View 5903M In the trailer harness at rear bumper 5904M In the rear trailer harness at rear bumper In the rear blackout B O harness at the In the rear blackout B O harness at the S907M rear bumper 5908M In the trailer harness at rear bumper S909M In the trailer harness at rear bumper Electrical Center Identification Views Relay Block I P an SEE me m Lg A 1704596 Legend 1 Cavity C Blackout B O Switch 4 Cavity E 24 Voltmeter Gage Ground 2 C8 Connector Location b Cavity F 24 Voltmeter Gage 3 C5 Connector Location 6 Relay Block I P 2005 LSSV Service Manual Supplement 8 164 Wiring Systems Relay Block I P C5 797092 e 12193928 e 6 Way F Metri Pack 280 Series Flexlock GY Circuit Wire Color No NotUsed LED Dimming PU WH 1382 Signal 2X3 1382 LED Dimming Signal 5G4 5X7 5YO TRW Selective Ride Control Switch Signal 7X3 Ignition 1 Voltage ZX3 24 Voltmeter Gage Supply Voltage Connector Part Information Connector Part Information 797092 e 12193930 e 6 Way F Metri Pack 280 Series Flexlock BK Circuit No Battery Positive Voltage 5G4 TRW 40 Blackout B O Service Switch 4540 1050 2340 243 Accessory Voltage 9L4 Battery Positive Voltage 5G4 5X7 5YO TRW Ground SX7 5Y0 5GY TRW 2
226. that are petroleum based or that contain acid or abrasives All cleaning agents should be flushed promptly and not allowed to dry on the surface Do not towel dry or wax the surface The windows should be washed with a water soaked cloth Do not rub dry Body Fiberglass Top The fiberglass top is a hard top cover supported by the bed rails and has side and back windows that are able to open and lock Maintenance Body The maintenance body is mounted to the pickup chassis using the same attachment locations as a pickup bed The maintenance body has multiple lighted locking doors and an open cargo space Ambulance Body The ambulance body mounts to special welded frame brackets There is also an HVAC system and special lighting Special Tools and Equipment Illustration oo Tool Number Description J 39400 A Halogen Leak Detector 2005 LSSV Service Manual Supplement Body Bumpers 8 27 Bumpers Specifications Fastener Tightening Specifications Specification Application English BONM 85 92 Nm 128 148 Nem 36 98 Nm 88 98 Nem 20 Nm 77 Nem 31 Nem 20 Nem 97 Nem 155 Nm 97 Nem 50 Nem Rear Bumper Side Frame Bolts Maintenance Body 120 N m 45 Nm Front Bumper Center Bolts Ambulance Maintenance Body 122 N m 90 Ib ft 2005 LSSV Service Manual Supplement 8 28 Bumpers Body Repair nstructions 1698258 1698258 3 4 Center Radiator Grille Brush Guard
227. the 4 bolts to 8 N m 70 Ib in 4 Install the front of the cargo cover to the front end rail as needed Refer to Cargo Cover Heplacement Cargo Cover Rear End Rail Replacement Removal Procedure 1 Remove the cargo cover from the end gate side of the cargo cover assembly Refer to Cargo Cover Heplacement 2 Remove the 4 bolts from the end gate rail as needed 3 Remove the 4 rivnuts by drilling out if damaged 2005 LSSV Service Manual Supplement Body Installation Procedure 1 Apply 2 sided foam tape to the underside of the rail 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 end gate rail over 4 rivnuts with 4 bolts Tighten Tighten the 4 bolts to 8 N m 70 Ib in 4 Install the cargo cover to the rear end as needed Refer to Cargo Cover Replacement 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 Install the 2 plastic bu
228. the backup lamp nuts 2 3 Disconnect the electrical connector 1 from the backup lamp 4 Remove the lamp assembly 1697906 2005 LSSV Service Manual Supplement Body Installation Procedure 1 Install the lamp assembly 2 Connect the electrical connector 1 to the backup lamp Notice Refer to Fastener Notice in Cautions and Notices 3 Install the nuts 2 for the backup lamp Tighten Tighten screws to 0 8 N m 7 lb in 4 Install the backup lamp bulb Refer to Backup Lamp Bulb Replacement Backup Lamp Bulb Replacement Removal Procedure 1 Using your hands turn the lens counterclockwise and remove from the lamp 2 Press down on the bulb and turn counterclockwise 3 Pull the bulb from the socket Installation Procedure Important Use an 1156 bulb for replacement 1 Install the bulb into the bulb socket 2 Press in and turn the bulb clockwise until fully seated Important Ensure that the gasket is fully installed on the lens 3 Install the lens onto the lamp and turn clockwise Be sure the lens is installed with the word TOP facing up 2005 LSSV Service Manual Supplement Lighting Systems 8 141 1697906 1692753 1692753 8 142 Lighting Systems Description and Operation Blackout B O Lighting Circuit Operation Voltage for connector C8 the blackout B O marker lamps is supplied through the accessory voltage circuit YL 243 located
229. the battery tray 2 and remove from frame Unsnap the positive battery cable cover Remove the negative and positive battery cables Remove the retainer bolt and remove battery 2005 LSSV Service Manual Supplement Engine Electrical 6 29 1704698 1704698 1704699 6 30 Engine Electrical Engine Installation Procedure 1 Install the battery in tray Notice Refer to Fastener Notice in Cautions and Notices 2 Install the battery retainer and tighten bolt Tighten Tighten retainer bolt to 25 N m 18 Ib ft 3 Install the positive and negative cables and tighten Tighten Tighten cables to 17 N m 13 Ib ft 4 Snap the positive battery cable cover closed 5 Lift the battery tray 2 onto the bolts 1 on the frame and tighten 6 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure 1704699 Relay Replacement 24V Generator Removal Procedure 1 Release the clip 2 securing the wiring harness to the underhood electrical center housing 2 Remove the 24V relay 1 from the underhood electrical center housing 1704700 3 Remove the connector position assurance CPA devices or secondary locks 4 Separate the relay 1 from the wiring harness connector 2 791846 2005 LSSV Service Manual Supplement Engine Installation Procedure 1 Connect the relay 1 to the wiring harness connector 2 2 Install any connector position assurance CPA
230. the repair Go to Step 13 13 Verify the system operation Do the horns operate properly System OK Go to Step 2 2005 LSSV Service Manual Supplement 8 66 Horns Body Horns Operate In Blackout B O Mode Sep l Acio Yes No Schematic Reference Horn Schematics Did you review Horns Description and Operation Go to Horn with 1 Blackout B O Control Go to Step 2 Circuit Operation Connect a test lamp between terminal 86 of the horn interrupt relay block and ground Does the test lamp illuminate Go to Step 4 Go to Step 3 Replace the horn interrupt relay 1 Disconnect the blackout B O service switch 2 Connect a test lamp between cavity C of the blackout B O switch connector and ground Does the test lamp illuminate Go to Step 6 Go to Step 5 Replace the blackout B O service switch Refer to Blackout B O Switch Replacement in Lighting Systems Did you complete the replacement Repair the short to voltage in the OG circuit 912 Did you complete the repair Go to Step 7 Verify the system operation amm ams Do the horns operate properly oystem OK Go to Step 2 Description and Operation ground to the coil of the horn relay When the coil of the relay is grounded the relay energizes and the contacts Horn with Blackout B O Control close applying battery voltage directly to the LH and RH horn Because the horns are grounded at ground Circuit Operation
231. the same locations as removed 3 Press the switch panel in place on the instrument panel cluster IPC trim plate bezel 4 Connect the switch panel cable to the receiver and secure with wiring harness straps in the same locations as removed 5 Install the I P knee bolster panel Refer to Knee Bolster Replacement in Instrument Panel Gages and Console in 2005 C K Truck Service Manual 6 Verify correct operation of the Tire Pressure Monitoring System 1693471 2005 LSSV Service Manual Supplement Suspension Tire Pressure Monitor Sensor 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 2005 C K Truck Service Manual 2 Remove the affected wheel Refer to Tire and Wheel Removal and Installation in Tires and Wheels in 2005 C K Truck Service Manual 3 Remove the pressure transmitter sensor assembly Refer to Tire Mounting and Dismounting Beadlock in Tires and Wheels 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 2005 C K Truck Service Man
232. 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 Remove the switch 4 from the panel 1 Installation Procedure 1 Install the switch 4 into the panel 1 2 Install the washer 3 and nut 2 and tighten 3 Install the accessory panel Refer to Accessory Instrument Panel VP Replacement in Instrument Panel Gages and Console 4 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2005 LSSV Service Manual Supplement Lighting Systems 8 119 1693483 1693483 8 120 Lighting Systems Body Topper Dome Lamp Switch Replacement Rear Removal Procedure 1 Remove the left rear tail turn signal lamp Refer to Tail Turn Signal Lamp Replacement Except Stepside in Lighting Systems in 2005 C K Truck Service Manual 2 Remove the connector 2 from the switch 3 From inside the cargo area remove the nut from the switch 4 Remove the switch 1 from the vehicle 1693482 Installation Procedure 1 Install the switch 1 into the vehicle 2 From inside the cargo area install the nut onto the switch 3 Install the connector 2 onto the switch 4 Install the left rear tail turn signal lamp Refer to Tail Turn Signal Lamp Replacement Except Stepside in Lighting Systems in 2005 C K Truck Service Manual 1693482 Blackout B O Switch Replacement
233. 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 Ib ft Tighten bolts 5 to 50 N m 37 Ib ft 3 Install the front support beams Refer to Front Support Beam Replacement 4 Install the rear support beams Refer to Rear Support Beam Replacement 5 Install the rear skid plate Refer to Rear Skid Plate Replacement 6 Install the front skid plate Refer to Front Skid Plate Replacement Rear 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 2005 C K Truck Service Manual 2 Remove the rear skid plate Refer to Rear Skid Plate Replacement 3 Remove the nuts 1 and bolts 2 4 Remove the support beams 3 Installation Procedure 1 Install the support beams 3 Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts 2 and nuts 1 Tighten Tighten front nuts and and bolts to 35 N m 26 Ib ft 3 Install the rear skid plate Refer to Rear Skid Plate Replacement 4 Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in the 2005 C K Truck Service Manual 2005 LSSV Service Manual Supplement Frame and Underbody 8 59 1700617 1700614 1700614 8 60 Frame and Underbody 1700616 170
234. 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 marker lamp connector 4 Install the harness into the original mounting location using the wiring harness strap 1693476 Taillamp Blackout B O Lamp Replacement Removal Procedure Important The taillamp and blackout lamps are replaced as an assembly 1 Ensure the headlamp switch is in the OFF position 2 Remove the 6 screws 1 holding the lamp to the body 3 Disconnect the electrical connector for the lamp harness 1692754 Installation Procedure 1 Connect the electrical connector for the lamp harness 2 Install the lamp onto the body lining up the holes with the body and rear lamp housing 3 Install the 6 screws 1 to the assembly and tighten 1692754 2005 LSSV Service Manual Supplement 8 134 Lighting Systems Body Taillamp Replacement Maintenance Body Removal Procedure 1 Ensure that the headlamp switch is in the OFF position 2 Remove the nuts 2 from the rear bumper 1 3 Remove the lamp from the rear bumper 4 Disconnect the lamp from the wiring harness 1693478 Installation Procedure 1 Install the wiring harness to the lamp Notice Refer to Fastener Notice in Cautions and Notices 2 Install the lamp onto the rear bumper 1 and insta
235. tor Inoperative en Vau Did you perform the Diagnostic System Check Vehicle Go to Diagnostic System Check Vehicle in Vehicle DTC Information in 2005 C K Truck Service Go to Step 2 Manual Using a DMM measure the voltage across the 24V battery Go to Battery terminals 18 0 28 5 V Inspection Test Is the voltage between the specified voltage Go to Step 3 Optima Using a DMM measure the voltage from the BATT terminal and ground Is the voltage greater than the specified voltage Go to Step 5 Go to Step 7 Connect a test lamp between ground terminal of the generator and battery negative Does the test lamp illuminate Go to Step 8 Go to Step 10 Connect a test lamp between terminal 30 of the 24V relay Go to Step 9 Go to Step 11 1 Start the engine 2 Using a DMM measure the voltage between the 7V generator terminal B and ground Is the voltage greater than the specified voltage Go to Step 4 Go to Step 6 and ground Does the test lamp illuminate 2005 LSSV Service Manual Supplement Engine Engine Electrical 6 27 24V Generator Inoperative cont d ve e ation H R Repair the generator voltage circuit for an open or high resistance Did you complete the repair Test the generator ground circuit for an open or high resistance Did you find and correct the condition Go to Step 17 Go to Step 10 Did you complete the replacement Se mei m E I Did the test lamp illuminate Go to Ste
236. ual 4 Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual 5 Program the system Refer to Tire Pressure Monitoring Sensor Programming 2005 LSSV Service Manual Supplement Tire Pressure Monitoring 3 41 1698015 1698016 1698016 3 42 Tire Pressure Monitoring 25 PSI Ld lt p 1641503 1641537 Suspension Tire Pressure Monitoring Sensor Programming Entering Programming Modes 1 Ensure the power is turned on 2 Press and hold set button in normal mode to enter programming modes e 2 seconds for Level 1 e 5 seconds for Level 2 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 35 psi 2 41 Bar 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 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 Oo BW Important Repeat programming steps 2 6 until Cold Inflation Pressure levels are set for all axles as desired 7 Pre
237. upport 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 Ib ft 3 Install the front cover bolts 2 Tighten Tighten bolts to 50 N m 37 Ib ft 2005 LSSV Service Manual Supplement Frame and Underbody 8 61 1700621 1700622 1700620 8 62 Frame and Underbody Body 4 Install the upper cover bolt Tighten Tighten bolts to 85 N m 63 Ib ft 5 Install the outer front bolts 1 Tighten Tighten bolts to 50 N m 37 Ib ft 6 Remove fuel tank support 7 Lower the vehicle Refer to Lifting and Jacking the Vehicle in General Information in 2005 C K Truck Service Manual 1700621 Trailer Hitch Reinforcement Plate Replacement Maintenance Body Removal Procedure 1 Remove the winch connector Refer to Rear Winch Harness and Connector Replacement LSSV or Rear Winch Harness and Connector Replacement Maintenance Body in Engine Electrical 2 Remove the bolts from the hitch 3 Remove the trailer hitch 2 and reinforcement plate 1 from the vehicle 1700803 Installation Procedure 1 Position trailer hitch 2 and reinforcement plate 1 to the vehicle Notice Refer to Fastener Notice in Cautions and Notices 2 Install the trailer hitch
238. ure 2005 LSSV Service Manual Supplement Engine Engine Electrical 6 33 Battery Cable Disconnect Connect Procedure Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Turn OFF all the lamps and accessories 2 Turn OFF the ignition 3 Remove the negative cable from the frame mounted battery 4 Remove the battery negative cable from the right underhood battery 1704765 5 Remove the negative cable of the 24V battery 6 Remove the positive cable of the 24V battery e LM QA TTL Y Z Ny nm KD TM Mim ti CTC 1704702 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 Ib ft 3 Install the negative battery cable to the right underhood battery Tighten Tighten the bolt to 17 N m 13 Ib ft NV e lt L w H f 45 eya C a y c9 Ta E Mim H UU 1704702 2005 LSSV Service Manual Supplement 6 34 Engine Electrical 1704765 1704703 1704707 Engine 4 Install the negative cable of the frame mounted battery Tighten Tighten the bolt to 17 N m 13 Ib ft Ve
239. utions 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 2005 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 Remove the nut 2 5 Lower the chassis accordingly in order to remove the reinforcement as necessary 6 Remove the lower reinforcement 1 from the vehicle Installation Procedure 1 Install the lower reinforcement 1 onto the radiator support 2 Raise the chassis accordingly 3 Perform the following procedure before installing the bolts e Remove all traces of the original adhesive patch Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry e Apply Threadlocker GM P N 12345493 Canadian P N 10953488 Notice Refer to Fastener Notice in Cautions and Notices 4 Install the body mount bolt and nut 2 Tighten Tighten body mounts to 70 N m 52 Ib ft 5 Remove the supports and lower the vehicle Front Skid Plate 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 2005 C K Truck Service Manual 2 Remove the bolts 1 from the front of the skid plate 3 Remove the bolts 3 from the rear of the skid
240. ve Cable Right 2005 LSSV Service Manual Supplement 6 18 Engine Electrical Engine Junction Block Underhood 1704696 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 2005 LSSV Service Manual Supplement 6 19 Engine Electrical Engine Generators Diesel 741105 Legend 3 Generator Left 12V 1 Generator Right 24V 2 Engine 2005 LSSV Service Manual Supplement 6 20 Engine Electrical Engine Left Front Corner of the Engine Compartment 1703357 Legend 1 Fuse Relay Center Underhood 3 Junction Block Underhood 2 Battery Left 24V 2005 LSSV Service Manual Supplement Engine Engine Electrical Connector End Views 24V Generator Relay 535912 e 12129716 s 4 Way F MP Series 280 GY Operator Field Duty SUE Cycle Signal 8002 UBEC Cavity A3 Connector Part Information 647991 15355066 e 4 Way F Metri Pack 150 Series Sealed NA Circuit Wire Color No Not Used 8014 Generator Field Connector Part Information Duty Cycle Signal NotUsed C D 2005 LSSV Service Manual Supplement Engine Electrical 6 21 Vehicle Load Disconnect Switch 1703358 e 4 Way E Wire Color No 12V Supply to Underhood BUS Electrical Center 12V Power Supply 24V Supply to
241. ve 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 Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts 1 to the assembly Tighten Tighten the bolts to 8 N m 70 Ib in 3 Install the lower rear window molding Refer to Molding Replacement Rear Window Lower in Interior Trim in the 2005 C K Truck Service Manual 2005 LSSV Service Manual Supplement Body Pioneer Tool Kit Bracket Replacement Removal Procedure 1 Remove the lower rear window molding Refer to Molding Replacement Rear Window Lower in Interior Trim in the 2005 C K Truck Service Manual 2 Remove the pioneer tool kit 3 Remove the 4 bolts 1 holding the bracket to the inner body 4 Remove the left bracket 2 or the right bracket 3 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 Ib in 3 Install the lower rear window molding Refer to Molding Replacement Rear Window Lower in Interior Trim in the 2005 C K Truck Service Manual 4 Install the pioneer tool kit Enhanced Mobility Package Jack Mounting Bracket Replacement In Vehicle Tire Carrier Removal Procedure Remo
242. ve the vehicle jack from the mount Remove the lower bracket nut 3 Remove the upper bracket bolt 1 and washer Remove the mounting bracket 2 e dim 2005 LSSV Service Manual Supplement Interior Trim 8 85 1702782 1702782 1703193 8 86 Interior Trim Body Installation Procedure 1 Install the mount bracket 2 in the mounting position Notice Refer to Fastener Notice in Cautions and Notices 2 Install the washer and upper bracket bolt 1 Tighten Tighten the bolt to 53 N m 39 Ib ft 3 Install the lower nut 3 Tighten Tighten the nut to 58 N m 39 Ib ft 4 Install the vehicle jack in the mount 1703193 Enhanced Mobility Package Jack Mounting Bracket Replacement Regular Cab Removal Procedure Slide the front seat to the forward position Remove the vehicle jack from the bracket Remove the bracket fasteners 1 Remove the mounting bracket BEN 1702785 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 Tighten Tighten the fasteners to 9 N m 80 Ib in 3 Install the vehicle jack in the bracket 1702785 2005 LSSV Service Manual Supplement Body Interior Trim 8 87 Enhanced Mobility Package Jack Mounting Bracket Replacement Extended Cab Removal Procedure Raise up the rear seat Remove the vehicle jack from the brac
243. vehicle hood 2 Remove the reinforcement bolt 2 3 Remove the fender support bolt 1 4 Using a flat bladed tool separate the upper 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 Apply panel bonding adhesive 5 to the upper reinforcement 3 Install upper reinforcement 3 onto the fender Notice Refer to Fastener Notice in Cautions and Notices 4 Install the fender 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 Ib in 6 Close the vehicle hood Verify correct fender alignment 2005 LSSV Service Manual Supplement Body Lower Front Fender Reinforcement Replacement Removal Procedure Open the vehicle hood Remove the reinforcement bolt 2 Remove the fender support bolt 1 Using a flat bladed tool separate the lower 4 reinforcement from the bonding adhesive securing them to the fender 5 Remove the lower reinforcement 4 from the fender BEN Installation Procedure 1 Remove any old panel bonding adhesive from the fender 2 Apply panel bonding adhesive 5 to the upper and lower reinforcements 3 Install lower reinforcement 4 onto the fender Notice Refer to Fastener Notice in Cautions and Notices 4 Install the fender b
244. ween the striker bottom and the latch pocket 4 Early carriers with a red striker sleeve will require a 5 mm 0 20 in shim all other carriers with a yellow sleeve will require a 3 mm 0 12 in shim Notice Refer to Fastener Notice in Cautions and Notices 5 Secure the latch bolts ensure that the cable tether is facing down Tighten Tighten latch bolts to 97 N m 72 Ib ft 6 Remove the shim 1 The carrier is now aligned and ready for use 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 With the aid of an assistant place the tire 3 into the carrier 2 Install the retainer 2 Notice Refer to Fastener Notice in Cautions and Notices 3 Install the washer 1 and wheel nut 4 Tighten Tighten the nut to allow a minimum of 5 visible threads on the stud 2005 LSSV Service Manual Supplement Tires and Wheels 3 29 1696177 1697958 1697958 3 30 Tires and Wheels Description and Operation General Description The spare tire is located under the rear end of non EMP vehicles For
245. y block connector C8 cavity C Go to Electrical Center circuit 40 OG wire and ground Identification Views in Does the test lamp illuminate Go to Step 17 Wiring Systems Locate and repair open in circuit 40 OG wire between P relay block connector C8 cavity C and the blackout B O service switch Did you complete the repair ml D I Seemok cote step Did you correct the condition System OK Go to Step 2 Diagnostic Information and Procedures Voltmeter Gage Lamp Inoperative Schematic Reference nterior Lights Dimming Schematics Connector Reference Lighting Systems Connector End Views Did you perform the Diagnostic System Check Vehicle Go to Diagnostic System Check Vehicle in Vehicle DTC Information in 2005 C K Truck Go to Step 2 Service Manual Connect a test lamp between cavity A of the voltmeter bulb and ground Does the test lamp illuminate Connect a self powered test lamp to cavity B and ground Does the test lamp illuminate Replace the voltmeter gage bulb Refer to Voltmeter Gage Lamp Replacement Did you complete the replacement ea D Locate and repair the open or high resistance in circuit 150 BE T o0 0 ya ie end geno Did you correct the condition System OK 4 Locate and repair the open or high resistance in circuit 9 Did you complete the repair Go to Step 7 2005 LSSV Service Manual Supplement 8 112 Lighting Systems Body Blackout B O Marker Lamps Always On Sche
246. y cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Install 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 Lamp Harness Replacement Rear 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 in Engine Electrical Disconnect the blackout B O lamp harness connectors from the B O marker lamp connectors 1 4 Disconnect the license plate lamp from the harness connector 2 Disconnect the commercial and the military connectors 6 7 from the harness Disconnect the relay connectors from the harness on the rear relay block 3 Disconnect the rear lamp harness connector 5 from the extension harness Remove the rear lamp harness from the vehicle 2005 LSSV Service Manual Supplement Body Installation Procedure 1 2 3 Install the rear lamp harness on the rear bumper Connect the rear lamp harness 5 to the extension harness Connect the relay connectors to the relays on the relay block 3 Connect the commercial and the military connectors 6 7 to the harness Connect the license plate lamp connector 2 to the harness Connect the blackout B O lam

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