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2003 EMP Service Manual Supplement

1. 8 22 Rear Support Beam Replacement Skid Plate 8 24 Rear Suspension Description Rear Enhanced Suspension 3 16 Rear Hydraulic Jounce Bumper 3 16 Rear Shock Absorber Cover Description 3 16 Rear Shock Absorber Description 3 16 Repair Rear Jounce Shock Absorber Mount 3 14 Rear Jounce Shock Absorber 4 2 3 15 Shock Absorber Cover Replacement XL to e ets Rhe as 3 12 Shock Absorber Cover Replacement Rigo eiie ptt te Is 3 13 Shock Absorber Replacement 3 12 Rear Suspension Fastener 3 11 Receiver 3 37 Reinforcement Brackets 8 17 S Schematics Tire Pressure Monitoring Tire Pressure Monitoring System 3 31 Shock Absorber Description Rear Shock Absorber Description 3 16 Shock Absorber Repair Rear Jounce Shock Absorber Mount 3 14 Rear Jounce Shock Absorber 3 15 Shock Absorber Cover Replacement Left ien e ORITUR 3 12 Shock Absorber Cover R
2. Enhanced Mobility Package 8 28 Frame and Underbod I I 4 Enhanced Mobility Package Body Accessorie Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 1 If removed install the caliper slide pins 1 Tighten Tighten slide pins to 180 N m 133 Ib ft 2 Install the caliper cover 2 3 Install the cover nuts 3 Tighten Tighten cover nuts 45 Nem 33 Ib ft 4 Remove supports and lower the vehicle Rear Mud Flap Replacement Removal Procedure 1 Remove the fender brace bolt 2 2 Remove the bolts 1 securing the flap to the body 3 Remove the mud flap 3 from the vehicle Installation Procedure 1 Install the mud flap 3 onto the body Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts 1 through the mud flap and into the body Tighten Tighten bolts to 4 N m 35 Ib in 3 Install the bolt 2 through the fender support and mud flap and into the body Tighten Tighten bolt to 25 Nem 18 Ib ft 5 Body and Accessories Frame and Underbody 8 29 Description and Operation Frame and Underbody Description Underbody Protection The underbody protection covers are mounted to the frame In off road conditions these covers will protect the enclosed components from damage The covers do not affect the operation of the vehicle and allow full access to maintenance items Enhanced Mo
3. 8 28 Rear Skid Plate Replacement 8 22 Frame and Underbody Description Frame and Underbody Description 8 29 Repair Center Frame Bracket Replacement Skid Plate ete ert 8 24 Rear Support Beam Replacement Skid Plate rna te teens 8 24 Specifications Fastener Tightening 8 21 Front Drive Axle Description Front Axle Vent Tube Filter 4 4 Repair Front Axle Vent Tube Filter Replacement 4 3 Front Support Beam Replacement Skid Plate 8 23 Front Suspension Description Front Enhanced 3 9 Front Hydraulic Jounce Bumper 3 9 Front Shock Absorber Description 3 9 Repair Jounce Shock Absorber Replacement 3 8 Repair Lower Jounce Control Arm Replacement 3 6 Shock Absorber Replacement 3 4 Front Suspension Enhanced Mobility Package 2 Specifications Fastener 3 3 Fuel Tank Protection Cover Replacement 8 26 Government Data Plate 0 5 Government Vehicle Data Plate Replacement 8 19 Identification Vehicle 0 3 Instrument Panel Gages and Console Repair Accessory Switch Panel
4. Enhanced Mobility Package Suspension 3 32 Tire Pressure Monitorin indui e dsiq Xie uonoun Jj 3HnsS3ud J9AI909 JOJlUOJA uonounf d l leued jueuunJjsu Josueg JOUN eJnssaJgd M1 Josueg eJnsseJgd Josueg JOjluoJA ensseJg JH Josueg eJnssaJgd 41 9815 PIIOS 9jelS PIOS r 9jelS PIOS 91815 PIIOS i Enhanced Mobility Package Suspension Tire Pressure Monitoring 3 33 Component Locator Function Display Unit 11 109 8 Legend 1 Programmed Wheel Position 8 Set Button 2 Alarm Light 9 Tire Rotation Program 3 Low Pressure Warning 10 Cold Pressure Program 4 Alert Indicator 11 Programming Mode 5 Learn Mode 12 Units of Pressure or Temperature 6 TIRE Button 13 Numerical Display 7 MODE Button 14 Towing Vehicle Indicator Enhanced Mobility Package 3 34 Tire Pressure Monitorin Suspension Relay Block IP Legend 1 Relay Block IP 2 C8 Connector Location Enhanced Mobility Package Suspension Tire Pressure Monitoring 3 35 Connector End Views Receiver Relay Block I P C8 C Li ES 15117 13478 Connector Part e 174823 1 Connector Part e 12193928 Information 2 4WayF information e 6 Way F Metri Pack 280 Series Flexlock CRM Pin Wire Circuit Function Colou
5. Tighten Tighten the nut to 53 N m 39 Ib ft 4 Install the vehicle jack in the mount Enhanced Mobility Package 3 28 Tires and Wheels Suspension Description and Operation Tires and Wheels Beadlock Tire System 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 monitoring system Enhanced Mobility Package Suspension Tires and Wheels 3 29 Special Tools and Equipment Illustration Tool Number Description 14999 D528235 H1 Run Flat Lubricant Enhanced Mobility Package 3 30 Tire Pressure Monitoring Suspension Tire Pressure Monitoring Specifications Tire Color Location Color Tire Number Tire Location Green 1 Right Front Red 2 Left Front Blue 3 Right Rear Yellow 4 Left Rear General Sp
6. 2 Route the air hose through the in the same location as removed 3 Install the air hose 2 onto the meter 1 Notice Refer to Fastener Notice in Cautions and Notices 4 Install the accessory panel 2 onto the I P and install bolts 1 Tighten Tighten bolts to 2 N m 18 Ib in 5 Push the I P cluster bezel back in place over the panel 6 Route the air hose 2 through the engine compartment as removed 7 Secure hose using clip 1 8 Push the hose 2 onto the tube adapter 3 Enhanced Mobility Package Engine Engine Controls 6 9 Air Flow Adapter Replacement Removal Procedure 1 Remove the air hose 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 hose 2 onto the adapter 3 Engine Control Module ECM Replacement The ECM for the enhanced mobility package requires a special ECM calibration Refer to Engine Control Module ECM Replacement in the C K Truck Service Manual and use the ECM Calibrations found in ECM Calibration Chart of this manual Enhanced Mobility Package 6 10 Engine Controls Engine Description and Operation Air Filter Restriction Indicator The air filter restrictor indicator gage is located in the accessory trim panel on the lower center of the instrument panel It monitors the e
7. Caution Refer to Vehicle Lifting Caution in Cautions and Notices Notice The front shock absorbers of the vehicle are multifunctional In addition to contributing to a smooth ride they also provide the only stop to the front suspension when fully extended Therefore when servicing the shock absorber service replacement shock absorbers must be equivalent to original shock absorbers in both extended length and strength Use of shocks not complying to original equipment or strength could result in suspension over travel or shock breakage Suspension over travel may result in suspension component breakage 1 Raise and Support the vehicle 2 Support the lower control arm with a jack stand 3 Hold the tennon end with a wrench while removing the nut 4 Remove the nut 5 Remove the upper insulator 1 Suspension Front Suspension 3 5 6 Remove the shock absorber mounting bolt 2 and nut 3 at the lower control arm 7 Remove the shock absorber 1 Installation Procedure 1 Install the shock absorber Insert the stem through the hole in the shock bracket on the frame 2 Align the shock absorber with the mounting holes in the lower control arm 3 Install the shock absorber through bolt 2 to the lower control arm and shock Notice Refer to Fastener Notice in Cautions and Notices 4 Install the shock absorber through bolt nut 3 Tighten Tighten the nut to 80 Nem 59 lb ft 5 Install the upper insulator
8. Right Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices 1 Raise and Support the vehicle 2 Remove the top cover bolt 1 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 Rear Suspension 3 1 Enhanced Mobility Package 3 3 14 Rear Suspension Suspension 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 Tighten lower shock bolt to 95 Nem 70 Ib ft Tighten shock cover bolts to 35 Nem 26 Ib ft Rear Jounce Shock Absorber Mount Replacement Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices 1 Raise and support the vehicle with safety stands 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 Enhanced Mobility Package Suspension Rear Suspension 3 15 Installation Procedure 1 Install the mount 3 and shock into position on the vehicl
9. Skid Plate 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 Body and Accessories Frame and Underbody 8 25 Installation Procedure 1 Install the brackets 1 2 and 6 on the vehicle Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts 3 4 and 5 and nuts 1 Tighten Tighten bolts 4 5 to 60 68 Nem 44 50 Ib ft Tighten bolts 3 to 40 47 Nem 30 35 Ib ft 3 Install the front support beams Refer to Front Support Beam Replacement Skid Plate 4 Install the rear support beams Refer to Rear Support Beam Replacement Skid Plate 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 Frame Bracket Replacement Skid Plate Removal Procedure 1 Remove the rear skid plate Refer to Rear Skid Plate Replacement 2 Remove the rear support beam Refer to Rear Support Beam Replacement Skid Plate 3 Remove the nuts 3 and bolts 1 4 Remove the rear mounts 2 and 4 Installation Procedure 1 Install the rear mounts 2 and 4 Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts 1 and nuts 3 Tighten Tighten nuts and bolts to 60 68 Nem 44 50 Ib ft 3 Install the rear support beams Refer to Rear Support Beam Replacement Skid Plate 4
10. Specification Application Metric English Accessory Panel Bolts 2 0 18 Ib in Enhanced Mobility Package 8 4 Instrument Panel Gages and Console Enhanced Mobility Package Body and Accessorie Repair Instructions Accessory Switch Panel Replacement Removal Procedure 1 Remove the lower bolts 1 from the accessory panel 2 Pull the portion of the I P cluster bezel above the accessory panel out enough to remove the panel 2 3 Disconnect the hose 2 from the air flow meter 1 4 Remove the I P knee bolster panel from the I P 5 Disconnect the display harness connector 1 from the tire pressure receiver 2 6 Remove the accessory panel from the I P Note display harness routing for installation 7 Remove the air flow meter from the panel Refer to Air Flow Meter Replacement in Engine Controls 8 Remove the tire pressure display from the panel Refer to Tire Pressure Display Replacement in Tires and Wheels 5 Body and Accessories Instrument Panel Gages and Console 8 5 Installation Procedure 1 Install the tire pressure display onto the panel Refer to Tire Inflation Pressure Display Replacement in Tires and Wheels 2 Install the air flow meter onto the panel Refer to Air Flow Meter Replacement in Engine Controls 3 Route the display wiring harness in the same locations as removed 4 Install the air flow meter hose 2 onto the port on the meter 1 Notice R
11. Information Labels Government Data Plate U S GOVERNMENT PROPERTY NOMENCLATURE TRUCK MCT EMP ENHANCED MOBILITY PACKAGE MAKE AND MODEL CHEVROLET K25753HD CURB WEIGHT MAX PAYLOAD GVWR GCWR 6570 LBS 2630 LBS 9200185 22000185 DATE OF DELIVERY 03 04 WARRANTY 36 MONTHS 36 000 MILES CONTRACT NO 4600001163 The government data plate is located on the left front inner door panel This label includes the contract No and vehicle weight specifications General Information 0 5 Enhanced Mobility Package 0 6 General Information General Information BLANK Enhanced Mobility Package General Information Maintenance and Lubrication Maintenance 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 C K Truck Owner s Manual e C K Truck Service Manual e Diesel Engine Owner s Manual Supplement If the concern still has not been corrected shut down the engine and notify your maintenance unit Periodic Maintenance Inspection e Inspect the condition of the headlamps tail lamps turn signals and side lamps before beginning to operate the vehicle each time Maintenance and Lubrication 0 7 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 the Front or Rear Axle Vent Tube Filter Replaceme
12. Install the rear skid plate Refer to Rear Skid Plate Replacement Enhanced Mobility Package 8 26 Frame and Underbod Body and Accessories Fuel Tank Protection Cover Replacement Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices 1 Raise and support the vehicle 2 Support the fuel tank cover 3 Remove the cover bolts 2 4 Remove the inner cover bolts 1 5 Remove the outer front cover bolts 1 from the support 2 6 Remove the cover bolts 1 remove support and lower the cover 2 Remove from the vehicle Enhanced Mobility Package Body and Accessories Frame and Underbody 8 27 Installation Procedure 1 Install the cover and support Notice Refer to Fastener Notice in Cautions and Notices 2 Install the cover bolt 1 Tighten Tighten bolt to 29 N m 21 Ib ft 3 Install the front cover bolts 2 Tighten Tighten bolts to 50 Nem 37 Ib ft 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 29 N m 21 Ib ft 6 Remove fuel tank support 7 Remove vehicle supports and lower the vehicle Rear Caliper Cover Replacement Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices 1 Raise and support the vehicle 2 Remove the cover nuts 3 3 Remove the caliper cover 2 4 lf damaged remove the caliper slide pins 1
13. Procedure Notice The filter arrow must point toward the transfer case 1 Install the filter 1 by pushing on the hoses 2 2 Remove safety stands 3 Lower the vehicle Enhanced Mobility Package 4 8 Transfer Case Driveline Axle Description and Operation Transfer Case Vent Tube Filter Description The vehicles feature a two speed transfer case A vent tube is mounted between the transmission and transfer case which attaches to a hose filter and vent cap The filter must be inspected occasionally to see if it needs to be replaced Refer to Periodic Maintenance Inspections in Maintenance and Lubrication in the Enhanced Mobility Package Owner s Manual Supplement Enhanced Mobility Package Engine Table of Contents 6 1 Section 6 Engine Engine Electrical 6 3 Air Flow Meter Hose Replacement 6 6 Specifications sees 6 3 Air Flow Adapter Replacement 6 9 Repair Instructions eese 6 4 Engine Control Module ECM Replacement 6 9 Battery Reinforcement Bracket Replacement 6 4 aee nis UA DE 5 Engine Controls 6 5 MUN A See Looe OEM ANIC 7 ERE 6 5 Engine Control Module 6 10 Repair Procedures 4 2 1 6 6 Air Flow Meter Replacement 6 6 Enhanced
14. Remove the upper shock absorber nut and bolt 3 Remove the lower shock absorber nut and bolt 4 Remove the shock absorber Installation Procedure 1 Install the shock absorber 2 Install the upper shock absorber nut and bolt Notice Refer to Fastener Notice in Cautions and Notices 3 Install the lower shock absorber nut and bolt Tighten Tighten the upper and lower nuts to 95 Nem 70 Ib ft 4 Remove the safety stands 5 Lower the vehicle Shock Absorber Cover Replacement Left Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices 1 Raise and support the vehicle 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 Suspension Installation Procedure 1 2 3 4 Install the shock cover pieces 1 5 7 Ensure that the tab in cover piece 1 fits into the slot in cover piece 5 Install bolt 2 at the top of the cover Install shock bolt 8 and nut 3 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 Tighten lower shock bolt to 95 N m 70 Ib ft Tighten shock cover bolts to 35 Nem 26 Ib ft Remove supports and lower the vehicle Shock Absorber Cover Replacement
15. Replacement 8 4 Instrument Panel Gages and Console Description Instrument Panel and Gages Description 8 6 Specifications Fastener 8 3 Interior Trim Repair Government Vehicle Data Plate 8 19 Jack Mounting Bracket Replacement 3 27 Jounce Shock Repair Jounce Shock Absorber Replacement 3 8 L Labels Government Data 0 5 Lower Jounce Repair Lower Jounce Control Arm Replacement 3 6 M Maintenance Owner Checks and 0 7 Periodic Maintenance Inspection 0 7 Monitor Display Replacement 3 37 P Pressure Transmitter Replacement 3 38 R Radiator Support Reinforcement Replacement Upper and 8 14 Rear Caliper Cover Replacement 8 27 Rear Drive Axle Description Rear Axle Vent Tube Filter 4 6 Repair Enhanced Mobility Package Index Rear Axle Vent Tube Filter Replacement 4 5 Rear Frame Bracket Replacement Skid Plate 8 25 Rear Mud Flap Replacement 8 28 Rear Skid Plate Replacement
16. Settings Tire Pressure Monitoring 3 31 T Tire Mounting and Dismounting Procedure 3 19 Tire Pressure Monitoring Component Function Display 3 33 Relay Block IP 3 34 Components Connector End Views 3 35 Diagnosis ErrorGode inepta et 3 36 Error Gode E2 5 cepere 3 36 Error Code ES iene ae 3 36 Error Code EA 1 usce 3 36 Repair Monitor Display Replacement 3 37 Pressure Transmitter Replacement 3 38 Receiver Replacement 3 37 Tire Pressure Monitoring Programming 3 39 Tire Pressure Monitoring Description General Description Tire Pressure Monitoring e ties 3 50 Special Tools and Equipment 3 51 Tire Pressure Monitoring Schematics Tire Pressure Monitoring System 3 31 Specifications General Specifications 3 30 Tire Color 3 30 eie eem rere tede 3 31 Tire Pressure Monitoring System Settings 3 31 Tires and Wheels Component Enhanced Mobility 3 18 Repair Jack Mounting Bracket Replacement 3 27 Spare Tire Carrier
17. Tires and Wheels Specifications Fastener Tightening Specifications Specification Application Metric English Jack Mounting Bracket Bolt 53 Nem 39 Ib ft Jack Mounting Bracket Nut 53 Nem 39 Ib ft Spare Tire Carrier Hex Bolts 35 Nem 26 Ib ft Spare Tire Carrier Torx Bolts 53 Nem 39 Ib ft Wheel Air Valve 7 8 Nem 5 6 lb ft Wheel Nuts First Pass 81 Nem 60 Ib ft Wheel Nuts Second Pass 102 108 Nem 75 80 Ib ft Enhanced Mobility Package 3 18 Tires and Wheels Suspension Component Locator Enhanced Mobility Wheel Legend 1 Rear Half of Wheel 4 O ring Seal 2 Beadlock 5 Front Half of Wheel 3 Tire 6 Tire Pressure Monitor Enhanced Mobility Package Suspension Tires and Wheels 3 19 Repair Instructions Tire Mounting and Dismounting Procedure Tools Required D528235 H1 Run Flat Lubricant Caution The wheel rim nuts must be replaced whenever the tire is changed e Failure to properly match tire and rim wheel sizes is dangerous Mounting a smaller diameter tire on a larger rim diameter rim wheel for example mounting a 16 inch tire on a 16 5 inch rim wheel can result in breaking the tire bead during mounting or airing The tire may then explode during inflation The explosion can hurl the tire and wheel into the air striking you or others Be sure the diameter shown on the tire exactly matches the diameter stamped on the rim wheel Excess paint can cause nut loose
18. 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 237 Nem 175 Ib ft Verify the control arm pivots freely and that the final alignment is correct Install the jounce shock absorber Refer to Front Jounce Shock Absorber Replacement Install the tire and wheel Refer to Tire and Wheel Replacement in Tires and Wheels Remove the safety stands and lower the vehicle Enhanced Mobility Package 3 8 Front Suspension Suspension Enhanced Mobility Package Jounce Shock Absorber Replacement Important Do not discharge the internal pressure of the jounce shock The loss of oil during discharge may affect the performance setting Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices Raise and support the vehicle with safety stands Remove the tire and wheel Refer to Tire and Wheel Replacement in Tires and Wheels Remove the lower shock nut and bolt 2 Remove the upper shock nut and bolt 1 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 Tig
19. button and the display will show the positions with the same ID s Use the MODE button to delete the sensor that is incorrect and the carry out the Learn operation for that position Notice f a sensor is programmed into an incorrect position on the vehicle during the Learn process it can be deleted by scrolling to the incorrect using the TIRE button and pressing the MODE button Once the Learn operation is completed as above to double check the sensors are in the correct position walk around the vehicle and activate each sensor with the wand The display should show all 4 wheel positions as expected EN 15079 Enhanced Mobility Package 3 48 Tire Pressure Monitoring Suspension Enhanced Mobility Package Changing Cold Inflation Pressure and Low Pressure Warning Settings Note The default settings for the Tire Pressure Monitoring system supplied with this vehicle are e Cold Inflation Pressure is 3 Bar 45 PSI Front Axle 4 Bar 60 PSI Rear Axle e Deviation Alert First Warning is 34 Bar 5 PSI all wheels This does not need to be changed e Low Pressure Warning Second Warning is 2 28 Bar 33 PSI Front Axle 3 Bar 45 PSI Rear Axle If itis necessary to change these settings because the vehicles tire pressure settings are changed follow the below instructions to accomplish this change Use the same instructions to change the system back to the original
20. mounted to the lower control arm 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 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 Enhanced Mobility Package Front Suspension 3 10 Suspension BLANK Enhanced Mobility Package Suspension Rear Suspension 3 11 Rear Suspension Specifications Fastener Tightening Specifications Specification Application Metric English Jounce Shock Frame Mount Bracket Bolts 72 Nem 53 Ib ft Jounce Shock to Mount Bolt 13 Nem 9 6 Ib in Shock Absorber Cover Bolts 35 Nem 26 Ib ft Shock Absorber Lower Nuts 95 Nem 70 Ib ft Enhanced Mobility Package 3 12 Rear Suspension Suspension Enhanced Mobility Package Repair Instructions Shock Absorber Replacement Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices Notice Original equipment shock absorbers serve additionally as suspension drop cutoffs Replacement shock absorbers must have a built in suspension cutoff feature and must not be longer than original shocks when they are fully extended or serious vehicle or component damage could result 1 Raise and support the vehicle 2
21. the right and left side 3 Remove the bumper support bolts 3 from the right and left side 4 Remove the side bumper support 2 from the right and left side 5 Remove the upper bolt 1 from the right and left side of the bumper 6 Remove the top inner top bumper bolts 1 from the right and left side 7 Remove the lower inner bumper bolt 2 from the right and left side Body and Accessories Bumpers 8 9 8 Remove the outer bumper bolts 1 from the right and left side 9 Support the bumper assembly using an approved support system 10 Remove the lower front bumper bolts 1 from the right and left side 11 Using the aid of an assistant remove the front bumper from the vehicle Installation Procedure 1 Using the aid of an assistant position the bumper assembly onto the vehicle 2 Support the bumper assembly by using an approved support system 3 Install the lower front bumper bolts 1 on the right and left side and hand tighten Enhanced Mobility Package Body and Accessories 8 10 Bumpers 4 Install the outer bumper bolts 1 on the right and left side and hand tighten 5 Install the inner lower bolts 2 on the right and left side and hand tighten 6 Install the inner top bumper bolts 1 on the right and left side and hand tighten 7 Install the upper bolt 1 on the right and left side and hand tighten Notice Refer to Fastener Notice in Cautions and Notices 8
22. to the shock absorber Install the nut to the tennon end Hand tighten only Remove the safety stands Lower the vehicle Hold the tennon end with a wrench while torquing the nut Tighten Tighten the nut to 20 Nem 15 Ib ft Enhanced Mobility Package 3 6 Front Suspension Suspension Enhanced Mobility Package Lower Jounce Control Arm Replacement Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices Raise and support the vehicle with safety stands Remove the tire and wheel Refer to Tire and Wheel Replacement in Tires and Wheels Remove the jounce shock absorber Refer to Front Jounce Shock Absorber Replacement Remove the 2 control arm brace bolts 1 Remove the control arm pivot bolt 2 and washer 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 Installation Procedure 1 Install the inner shim 1 and control arm 3 onto the pivot nut 4 Suspension Front Suspension 3 7 2 Verify that the alignment of the jounce lower control arm 3 2 and stabilizer bushing link 1 of the factory control arm are within the specification Add shims until the specification is correct Specification A 5mm 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
23. 00 0125 LF Interrogator Wand Enhanced Mobility Package 3 52 Tire Pressure Monitoring Suspension BLANK Enhanced Mobility Package Driveline Axle Table of Contents 4 1 Section 4 Driveline Axle Front Drive Axle 4 3 Transfer Case iori 4 7 Repair 4 2 4 3 Repair 4 22 4 7 Front Axle Vent Tube Filter Replacement 4 3 Transfer Case Vent Tube Filter Replacement 4 7 Description and Operation 4 4 Description and Operation 4 8 Front Axle Vent Tube Filter Description 4 4 Transfer Case Vent Tube Filter Description 4 8 Rear Drive Axle 4 5 Repair 4 4 44 21 4 5 Rear Axle Vent Tube Filter Replacement 4 5 Description and Operation 4 6 Rear Axle Vent Tube Filter Description 4 6 Enhanced Mobility Package 4 2 Table of Contents Driveline Axle BLANK Enhanced Mobility Package Driveline Axle Front Drive Axle Repair Instructions Front Axle Vent Tube Filter Replacement Removal Procedure 1 Remove the hoses 2 from the filter 1 2 Remove the filter 1 and discard 3 Inspect the hoses and reducers for damage or w
24. 1 Remove the front skid plate Refer to Front Skid Plate Replacement 2 Remove the bolts 1 and nuts 2 3 Remove the support beam 3 and 4 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 Tighten nuts and bolts to 35 N m 26 Ib ft 3 Install the front skid plate Refer to Front Skid Plate Replacement Frame and Underbody 8 2 Enhanced Mobility Package 3 8 24 Frame and Underbod Body and Accessories Enhanced Mobility Package Rear Support Beam Replacement Skid Plate Removal Procedure 1 Remove the rear skid plate Refer to rear Skid Plate Replacement 2 Remove the nuts 1 and bolts 2 3 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 nuts and bolts to 35 Nem 26 Ib ft 3 Install the rear skid plate Refer to Rear Skid Plate Replacement Center Frame Bracket Replacement Skid Plate 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 Rear Support Beam Replacement Skid Plate 4 Remove the front support beams Refer to Front Support Beam Replacement
25. Align the front bumper to the vehicle and tighten all bolts Tighten Tighten bolts to 85 Nem 63 Ib ft Enhanced Mobility Package Body and Accessories Bumpers 8 11 9 Install the bumper support 2 and bolt 1 Tighten Tighten bolt to 85 Nem 63 Ib ft 10 Install the bumper support bolts 3 Tighten Tighten bolts to 55 N m 41 Ib ft 11 Remove supports and lower the vehicle Enhanced Mobility Package 8 12 Bumpers Body and Accessories Description and Operation Bumpers The front bumper assembly provided in this package is rugged and durable and is designed for the rigors of limited off road conditions The full width bumper and brush guard help protect the vehicles front end and front fenders from damage Enhanced Mobility Package Body and Accessories Body Front End 8 13 Body Front End Specifications Fastener Tightening Specifications Specification Application Metric English Fender Bolt 25 N m 18 Ib ft Front Body Mount Nut 70 Nem 52 Ib ft Fender Reinforcement Bolt 4 Nem 35 Ib in Enhanced Mobility Package 8 14 Body Front End Body and Accessories Repair Instructions Radiator Support Reinforcement Replacement Upper and Lower Removal Procedure Important Ensure that the vehicle is unloaded prior to reinforcement replacement Caution Refer to Vehicle Lifting Caution in Cautions and Notices 1 Raise and support the vehicle 2 Remove the front bumper R
26. GENERAL MOTORS ENHANCED MOBILITY PACKAGE SERVICE MANUAL SUPPLEMENT BLANK Preface Preface 1 Preface Caution Caution To reduce the chance of personal injury and or property damage carefully observe the instructions that follow The service manuals of General Motors Corporation are intended for use by professional qualified technicians Attempting repairs or service without the appropriate training tools and equipment could cause injury to you or others This could also damage the vehicle or cause the vehicle to operate improperly Proper vehicle service and repair are important to the safety of the service technician and to the safe reliable operation of all motor vehicles If you need to replace a part use the same part number or an equivalent part Do not use a replacement part of lesser quality The service procedures we recommend and describe in this service manual are effective methods of performing service and repair Some of the procedures require the use of tools that are designed for specific purposes Accordingly any person who intends to use a replacement part a service procedure or a tool that is not recommended by General Motors must first establish that there is no jeopardy to personal safety or to the safe operation of the vehicle This manual contains various Cautions and Notices that you must observe carefully to reduce the risk of personal injury during service or repair Improper service or rep
27. Mobility Package 6 2 Table of Contents Engine BLANK Enhanced Mobility Package Engine Engine Electrical 6 3 Engine Electrical Specifications Fastener Tightening Specifications Application Specification Metric English Battery Retainer Bolts 9 Nem 7 lb ft Enhanced Mobility Package 6 4 Engine Electrical Engine Repair Instructions Battery Reinforcement Bracket Replacement Removal Procedure 1 Remove the bracket bolts 1 2 Remove the bracket 2 from the battery Installation Procedure 1 Install the bracket 2 onto the battery Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts 1 and tighten Tighten Tighten bracket bolts to 9 N m 7 Ib ft Enhanced Mobility Package Engine Engine Controls 6 5 Engine Controls Specifications Fastener Tightening Specifications Application Specification Metric English Accessory Panel Bolts 2 0 18 Ib in ECM Calibration Model Engine Transmission New Tire Size Calibration P N Year 2003 2004 LB M74 LT285 75R18 15130245 628 Rev Mile 392 Rev per Kilometer 2004 LLY M74 LT285 75R18 15130246 628 Rev Mile 392 Rev per Kilometer 2005 LLY M74 LT285 75R18 15130247 628 Rev Mile 392 Rev per Kilometer Please refer to the light duty series GM BODY BUILDER BOOK for further general information regarding vehicle modification New calibratio
28. PSI Enter Level 1 Programming Mode To enter this function press the MODE button until the flat tire icon and pressure units are displayed Press the TIRE button to scroll to the desired axle The tires of the selected axle are filled in Suspension Note 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 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 Note This function sets the pressure deviation alert threshold for all tires Factory Default 35 Bar 5 PSI 1 2 3 Enter Level 1 Programming Mode To enter this function press the MODE button until the icon and pressure units are displayed Press the TIRE 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 Tire Pressure Monitoring 3 4 Enhanced Mobility Package 1 3 42 Tire Pressure Moni
29. Replacement 3 26 Repair Spare Tire 3 26 Tire Mounting and Dismounting Procedure ete Ie tds 3 19 Special Tools and Equipment 3 29 Tires and Wheels Description Beadlock Tire System 3 28 Fastener 3 17 Transfer Case Description Transfer Case Vent Tube Filter 4 8 Repair Transfer Case Vent Tube Filter 4 7 Upper and Lower Fender Reinforcement Replacement sss 8 16 Vehicle Identification 2042 2 0 3 Enhanced Mobility Package UU index BLANK Enhanced Mobility Package
30. Tire Rotation Note 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 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 Press the MODE button to select it for editing 5 Note the color of the washer on the physical tire at the currently selected position gt 6 Use the transmitter location specifications chart in Description and Operation to determine the number corresponding to color noted in step 5 7 Use the TIRE or MODE button to adjust the value to the number determined in step 6 8 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 9 Press the SET button to save and exit this mode If more than one tire location contain the same sensor number the display will prompt an error with the conflicting tires filled in and the associated sensor number Press any button to return the tire selection menu and make necessary corrections Err 15079 Enhanced Mobility Package 3 A4 Tire Pressure Monitorin Suspension 15080 Enhanced Mobility Package 10 Press the SET button again t
31. air may damage the vehicle or render the vehicle unsafe For Cautions and Notices refer to Cautions and Notices in the C K Truck Service Manual These Cautions and Notices are not exhaustive General Motors cannot possibly warn of all potentially hazardous consequences of your failure to follow these instructions This manual covers service procedures to vehicles that are equipped with a Supplemental Inflatable Restraint SIR Refer to the Cautions in Cautions and Notices and in Restraints Refer to SIR component and wiring location views in Restraints before performing a service on or around SIR components or wiring Failure to follow these Cautions could cause air bag deployment personal injury or otherwise unneeded SIR repairs In order to help avoid accidental air bag deployment and personal injury whenever you service a vehicle that requires repair of the SIR and another vehicle system we recommend that you first repair the SIR then go on to the other system Preface 2 Preface BLANK Preface Preface 3 Enhanced Mobility Package Service Manual Supplement This manual provides information on the diagnosis the service procedures the adjustments and the specifications for the GM Enhanced Mobility Package Pickup Information on transmission unit repair overhaul can be found in the Transmission Transaxle Transfer Case Unit Repair Manual TURM available separately The TURM contains information on automatic and
32. bility Package Body and Accessories Frame and Underbody 8 30 BLANK Enhanced Mobility Package Index A Accessory Switch Panel Replacement 8 4 Air Filter Restriction 6 10 Air Flow Adapter 6 9 Air Flow Meter Hose Replacement 6 6 Air Flow Meter 6 6 Axle Description Front Axle Vent Tube Filter Description 4 4 Rear Vent Tube Filter Description 4 6 Repair Front Axle Vent Tube Filter Replacement 4 3 Rear Vent Tube Filter Replacement 4 5 B Battery Reinforcement Bracket Replacement 6 4 Beadlock Tire Tires and Wheel Description Beadlock Tire System 3 28 Body Front End Description Reinforcement Brackets 8 17 Repair Radiator Support Reinforcement Replacement Upper and Lower 8 14 Upper and Lower Fender Reinforcement Replacement ttt ere 8 16 Specifications Fastener 8 13 Bumpers Repair Bumper Replacement Front 8 8 Bumpers Description B imbpets Saati 8 12 Specifications Fastener Tightening Specifications 8 7 Center Frame Bracket Rep
33. draulic Jounce 3 16 Tires and Wheels 3 17 Specifications eene 3 17 Component 3 18 Repair 3 19 Tire Mounting Dismounting Procedure 3 19 Spare Tire 3 26 Spare Tire Carrier Replacement 3 26 Jack Mounting Bracket Replacement 3 27 Description and Operation 3 28 Tires and 3 28 Special Tools and Equipment 3 29 Enhanced Mobility Package 3 2 Table of Contents Suspension BLANK Enhanced Mobility Package Suspension Front Suspension 3 3 Front Suspension Specifications Fastener Tightening Specifications Specification Application Metric English Jounce Shock Lower Bolt 125 Nem 92 Ib ft Jounce Shock Upper Bolt 125 Nem 92 Ib ft Lower Jounce Control Arm Brace Bolt 72 Nem 53 Ib ft Lower Jounce Control Arm Pivot Bolt 237 Nem 175 Ib ft Shock Absorber Nut 80 N m 59 Ib ft Shock Absorber Tennon Nut 20 N m 15 Ib ft Enhanced Mobility Package 3 4 Front Suspension Suspension Enhanced Mobility Package Repair Instructions Shock Absorber Replacement Removal Procedure
34. e 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 Remove safety stands and lower vehicle Rear Jounce Shock Absorber Replacement 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 slipping 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 13 N m 9 6 Ib in 3 Install the rear jounce shock mount Refer to Rear Jounce Shock Mount Replacement Enhanced Mobility Package 3 16 Rear Suspension 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
35. e Refer to Fastener Notice in Cautions and Notices 3 Install the tire Refer to Tire and Wheel Removal and Installation in the C K Truck Service Manual 4 Remove the supports and lower the vehicle 5 Program the system Refer to Tire Pressure Monitoring Programming Tire Pressure Monitoring Programming Entering Programming Modes 1 Ensure the power is turned on 2 Press and hold set button in normal mode to enter programming modes 2 seconds to Level 1 e 5 seconds for Level 2 Enhanced Mobility Package 3 40 Tire Pressure Monitorin Suspension Enhanced Mobility Package Level 1 Cold Inflation Pressure Note This function changes the cold inflation pressure for each axle Factory default 2 08 Bar 30 PSI Enter Level 1 Programming Mode 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 Repeat programming steps 2 6 until Cold Inflation Pressure levels are set for all axles as desired T 8 Press the SET button to exit Press the SET button again to revert to normal view Low Pressure Warning Note This function changes to low pressure warning threshold for each axle Factory default 1 25 Bar 18
36. e vehicle chassis and tighten the body mount nuts Tighten Tighten body mounts to 70 N m 52 Ib ft 7 Remove the supports and lower the vehicle Enhanced Mobility Package 8 16 Body Front End Body and Accessories Enhanced Mobility Package Upper and Lower 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 upper 3 and lower 4 reinforcement from the bonding adhesive securing them to the fender 5 Remove the upper 3 and lower 4 reinforcements from the fender PONS 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 upper 3 and lower 4 reinforcements 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 Ib ft 5 Install the reinforcement bolt 2 Tighten Tighten the bolt to 4 Nem 35 Ib in 6 Close the vehicle hood Verify correct fender alignment Body and Accessories Body Front End 8 17 Description and Operation Reinforcement Brackets Reinforcement brackets are used to minimize structural damage cause by severe off road conditions The reinforcement brackets minimize or lessen the concentration of stress in small areas of the radiator and fe
37. ear Replace as needed If replacing the hose the length of the new hose must match the length of the old hose Installation Procedure Notice The filter arrow must point toward the axle vent pipe 1 Install the filter 1 by pushing on the hoses 2 Front Drive Axle 4 3 Enhanced Mobility Package 4 4 Front Drive Axle Description and Operation Front Axle Vent Tube Filter Description The front axle is specially equipped with a vent tube filter to protect the axle from contaminants found in the off road environment The vent filter is attached to a hose with a vented cap at the end and is mounted in the engine compartment next to the left inner wheel housing The filter must be inspected occasionally to see if it needs to be replaced Refer to Periodic Maintenance Inspections in Maintenance and Lubrication in the Enhanced Mobility Package Owner s Manual Supplement Enhanced Mobility Package Driveline Axle Driveline Axle Rear Drive Axle 4 5 Rear Drive Axle Repair Instructions Rear Axle Vent Tube Filter Replacement Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions F Notices 1 Raise and support the vehicle 2 Remove the hoses 2 from the filter 1 3 Remove the filter and discard 4 Inspect the hoses and reducers for damage or wear Replace as needed If replacing the hose the length of the new hose must match the length of the old hose Installation P
38. ecifications Application Specification Metric English Function Display Power Consumption 80 ma min to 110 ma max Operating Temperature 29 C to 85 C 20 F to 185 F Display Dimensions 71mm x 19mm x 42 2 8 in x 0 74 in x 1 64 mm in Display Weight 43 gm 1 502 Operating Humidity 100 Non Condensing Function Cold Tire Inflation 0 to 5 20 Bar 10 to 76 PSI Low Pressure Warning 33 to 6 35 Bar 5 to 95 PSI Pressure Deviation Alert 15 1 40 Bar 2 to 20 PSI High Temperature Alert 30 C to 120 C 86 F to 248 F Slope 10 160 Units of Temperature C Units of Pressure Bar PSI Number of Tires Monitored 20 Enhanced Mobility Package Suspension Tire Pressure Monitoring 3 31 Tire Pressure Monitoring System Settings Terrain Cold Inflation Pressure Low Pressure Warning Slope Highway 2 76 Bar 40 PSI 2 07 Bar 30 PSI 51 Cross Country 1 60 Bar 23 PSI 1 17 Bar 17 PSI 34 Mud Sand Snow 1 24 Bar 18 PSI 0 90 Bar 13 PSI 29 Tire Pressure Terrain Deflection Max Speed Load Min Inflation Highway 1896 149 km h 93 mph 1043 kg 2300 Ibs 2 76 Bar 40 PSI Cross Country 2596 48 km h 30 mph 1043 kg 2300 Ibs 1 60 Bar 23 PSI Mud Sand Snow 30 16 km h 10 mph 1043 kg 2300 Ibs 1 24 Bar 18 PSI Schematic and Routing Diagrams Tire Pressure Monitoring System
39. efer to Bumper Replacement in Bumpers 3 Remove the body mount nut and bolt of the reinforcement that is being replaced Loosen the other body mount nuts 4 Properly support the body in the area that the mounts will be replaced Caution When you remove the reinforcements do NOT separate the frame from the body more than is necessary Possible personal injury and damage to multiple parts may result if you do not follow the guidelines outlined below Intermediate steering shaft not allow the shaft to extend more than 25 mm 1 in e Park Brake Cable Leave slack in the cable e Body ground straps Leave slack in the wire 5 Lower the chassis accordingly in order to remove the reinforcement as necessary 6 Using a flat bladed tool separate the upper reinforcement 2 from the radiator support 3 Enhanced Mobility Package Body Front End 8 15 Body and Accessories 7 Using a flat bladed tool Separate the lower reinforcement 2 8 Remove the radiator support reinforcements from the vehicle Installation Procedure 1 Remove any old panel bonding adhesive from the radiator support 2 Apply panel bonding adhesive 4 to the upper reinforcement 2 3 Apply panel bonding adhesive 1 to the lower reinforcement 2 4 Install the upper reinforcement onto the radiator support Notice Refer to Fastener Notice in Cautions and Notices 5 Install the body mount bolt and nut 3 6 Raise th
40. efer to Fastener Notice in Cautions and Notices 5 Install the necessary panel 2 onto the and install bolts 1 Tighten Tighten bolts to 2 N m 18 Ib in 6 Push the cluster bezel back in place over the panel 7 Install the connector 1 of the display into the tire pressure receiver 2 8 Install the I P knee bolster panel Enhanced Mobility Package 8 6 Instrument Panel Gages and Console Body and Accessories Description and Operation Instrument Panel and Gages Description The instrument panel has been modified with a accessory panel mounted below the accessory power outlets 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 Enhanced Mobility Package Body and Accessories Bumpers 8 7 Bumpers Specifications Fastener Tightening Specifications Specification Application English Front Bumper Bolts 63 Ib ft Front Bumper Support to Bumper Bolts 63 Ib ft Front Bumper Support to Frame Bolts 55 Nem 41 Ib ft Enhanced Mobility Package 8 8 Bumpers Body and Accessories Enhanced Mobility Package Repair Instructions Bumper Replacement Front Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices 1 Raise and support the vehicle 2 Remove the bumper support bolts 1 from
41. eplacement Right cee e D ERE 3 13 Shock Absorber Replacement diee 3 4 acu 3 12 Shock Absorber Description Front Shock Absorber Description 3 9 Shock Absorber Cover Description Rear Shock Absorber Cover Description 3 16 Spare Tire Carrier Replacement 3 26 Spare Tire Replacement 3 26 Special Tools and Equipment Tire Pressure Monitoring 3 51 Tires and 0202 3 29 Specifications ECM Calibration Engine Controls see 6 5 Index Specifications Fastener Tightening Body Front End nite td 8 13 teta adiing 8 7 Engine Controls sss 6 5 Engine 2 2 424 422 6 3 Frame and 8 21 Front 3 3 Instrument Panel Gages and Console 8 3 Rear Suspension 3 11 Tires and 3 17 General Specifications Tire Pressure Monitoring 3 30 Tire Color Location Tire Pressure Monitoring 3 30 Tire Pressure Tire Pressure Monitoring 3 31 Tire Pressure Monitoring System
42. er 8 14 Upper and Lower Fender Reinforcement Replacement sss 8 16 Description and Operation 8 17 Reinforcement Brackets 8 17 Interior Trim uice Ree cues 8 19 Repair Instructions 224 2 8 19 Government Vehicle Data Plate Replacement 8 19 Frame and Underbody 8 21 Specificatlons ce nextadeecee teer 8 21 Repair Instructions 22 8 22 Front Skid Plate Replacement 8 22 Rear Skid Plate Replacement 8 22 Front Support Beam Replacement Skid Plate sse aM 8 23 Rear Support Beam Replacement Skid Plate see Rite 8 24 Center Frame Bracket Replacement Skid Plate temere Ora DR 8 24 Rear Frame Bracket Replacement Skid Plate heroe 8 25 Fuel Tank Protection Cover Replacement 8 26 Rear Caliper Cover Replacement 8 27 Rear Mud Flap Replacement 8 28 Description and Operation 8 29 Frame and Underbody Description 8 29 Enhanced Mobility Package 8 2 Table of Contents Body and Accessories BLANK Enhanced Mobility Package Body and Accessories Instrument Panel Gages and Console 8 3 Instrument Panel Gages and Console Specifications Fastener Tightening Specifications
43. escription 3 9 Error Code E2 ee Earned 3 36 Front Hydraulic Jounce Bumper Description 3 9 Error Code eee 3 36 Rear Suspension 3 11 Error Code 4 3 36 Specifications 3 11 Repair Procedures 4 44 4 3 37 Repair 2 0 5 3 12 Receiver 3 37 Shock Absorber 3 12 Monitor Display Replacement 3 37 Shock Absorber Cover Replacement Left 3 12 Pressure Transmitter Replacement c 3 38 Shock Absorber Cover Replacement Right 3 13 Tire Pressure Monitoring Programming 3 39 Rear Jounce Shock Absorber Mount Description and Operation E CCC TERT 3 50 Replacement ah EE DELE T pU 3 14 General Description Tire Pressure Rear Jounce Shock Absorber Replacement 3 15 Monitoring sed anaes arse sed KARA PESES 3 50 Description and 3 16 Special Tools and Equipment 3 51 Rear Enhanced 3 16 Rear Shock Absorber Description 3 16 Rear Shock Absorber Cover Description 3 16 Rear Hy
44. essage and the display with the conflicting tires filled in If so indicated repeat the programming procedure above Learn Procedure With Special Tool Tools Required 200 0125 LF Interrogator Wand Note The SmarTire receiver that is installed on the vehicle needs to have the unique sensor identification code for each wheel position programmed into it to ensure proper operation of the system Each wheel assembly has a sensor in it that can be activated using the LF wand 1 that has been supplied for this purpose 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 receivers to be carried out very easily To use the wand to activate the sensor press the button on the side of the wand a small red LED will illuminate to show it is working if this does not happen the replace the batteries and place the square head of the wand flat against the tire sidewall The wand can activate the sensor within a 60 degree arc of the sensor on the rim If the location of the sensor is not known the wand can be slowly moved around the circumference of the tire until the sensor is activated The Learn operation is carried out by using the Full Function Display that is already installed in each vehicle Suspension Tire Pressure Monit
45. flash 5 Anew transmitter identification can be learned in two ways Vigorously shake the transmitter to provoke a transmission By inflating or deflating the tire by more than 0 2 Bar 3 PSI Notice This method must be carried out while the transmitters are in gauge fill mode This mode is entered for 15 minutes after the vehicle has been driven above 10 kph 6 mph Each transmitter learn operation must be carried out at least 90 seconds apart If it is not possible to complete the learn operation for all transmitters within 15 minutes the vehicle must again be driven above 10 kph 6 mph and then the process can be continued Note To prevent the last identification 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 6 To remove the transmitter from the selected tire location press the MODE button 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 and exit 15084 Enhanced Mobility Package 3 46 Tire Pressure Monitorin Suspension Enhanced Mobility Package 15079 Notice lf 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 m
46. ft Enhanced Mobility Package 8 22 Frame and Underbod Enhanced Mobility Package Body and Accessorie Repair Instructions Front Skid Plate Replacement Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices 1 2 3 4 Raise and support the vehicle Remove the bolts 1 from the front of the skid plate Remove the bolts 3 from the rear of the skid plate Remove the skid plate 2 from the vehicle Installation Procedure 1 Install the skid plate 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 Install the front bolts 1 Tighten Tighten the bolts to 21 N m 15 Ib ft Remove the safety stands Lower the vehicle Rear Skid Plate Replacement Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices 1 Raise and support the vehicle 2 Support the skid plate and remove the bolts 2 3 Remove the support and remove the skid plate 1 5 Body and Accessories Installation Procedure 1 Install the skid plate support Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts 2 and remove support Tighten Tighten bolts to 35 N m 26 Ib ft 3 Remove the safety stands 4 Lower the vehicle Front Support Beam Replacement Skid Plate Removal Procedure
47. he Enhanced Mobility Package series military pickup models derive from standard commercial vehicles The pickup is a 2500HD or 1 ton Silverado All vehicles have rugged designs intended for all types of roads or 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 Enhanced Mobility Package Vehicle The pickup vehicles are equipped with a 6 6L Turbo diesel engine with a 5 speed Allison automatic transmission and 2 speed transfer case Each vehicle is equipped with enhanced suspension 4 wheel anti lock brakes a locking differential on off road beadlock tires and tire pressure monitoring system General Information 0 3 Enhanced Mobility Package 0 4 General Information Equipment Options Commercial Utility Cargo Vehicle EMP Specifications Options Your vehicle may be equipped with any combination of options General Information Description Trailer Light Connection Heavy Duty Front and Rear Shocks Transfer Case Differential Vent Filter Government Data Plate Factory Rear Receiver Hitch Enhanced Suspension Heavy Duty Front Bumper with Brush Guard Sliding Rear Window Tire Pressure Monitoring System Beadlock Tires Interior Air Cleaner Restrictor Gage Enhanced Mobility Package General
48. hten Tighten bolt to 125 Nem 92 Ib ft Install the lower nut and bolt 2 Tighten Tighten bolt to 125 Nem 92 Ib ft Install the tire and wheel Refer to Tire and Wheel Replacement in Tires and Wheels Remove the safety stands and lower the vehicle Suspension Front Suspension 3 9 Description and Operation Front Enhanced Suspension The front suspension has 2 primary purposes e solate the driver from irregularities in the road surface e 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 Front Shock Absorber Description A shock absorber is a basic hydraulic cylinder 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 top of the shock is mounted to the frame and the lower is
49. ilitary organization e Your dealership s Military organization s phone number e The model year and the vehicle line e publication part number if present e The vehicle identification number of the vehicle being worked on e The service manual section and page number s e applicable electronic information element identification numbers e Adescriptive explanation of your concern The GM service manual phone personnel will respond to your concerns in the following ways e delivering your concern to the manual s author e eliciting a response from the author e By supplying you with an answer to your concerns For paper manual users The GM service manual phone personnel will also explain how to send in examples or marked up pages The GM service manual comment telephone numbers do not provide technical assistance For technical assistance contact your regular technical assistance source United States Please call the following number Monday through Friday 8 a m 8 p m eastern time with your comments 1 800 828 6860 or fax to number 248 265 9327 United States Owner Operator Vehicle owners or operators are encouraged to address their comments and concerns to the applicable Customer Assistance Center The phone number and address of the Customer Assistance Center are in the Owner s Manual General Motors Defense Contact Information Refer to the web at www gm defense com Mailing Address GM Defense Military T
50. insert down enough to expose the sensor 10 Remove the sensor from the beadlock insert Enhanced Mobility Package 3 22 Tires and Wheels Suspension 11 Stand the tire on end allowing one side of the beadlock to fall off center into the tire chamber 12 Place the tire back on the ground and compress the beadlock in an oval shape and twist and pull out of the tire cavity 14989 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 any dirt or foreign materials Clean the beadlock edges with a clean towel and remove any foreign materials 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 halfs 2 Inspect the following areas Enhanced Mobility Package 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 Suspension Tires and Wheels 3 23 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 Note sensor color for reference of tire location on vehicle 3 Install the tire pressure sensor assemble 1 w
51. is in motion Two identical direct dual action shock absorbers and hydraulic jounce bumpers provide the ride control The jounce bumpers are frame mounted The rear spring steel stabilizing shaft helps minimize body roll and sway during cornering The rear stabilizer shaft is connected to the rear axle and the frame with the following components e The rubber insulators e The clamps e The link assemblies 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 cylinder 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 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 Enhanced Mobility Package Suspension Tires and Wheels 3 17
52. ithin the beadlock groove 2 Important The sensor must be opposite one of the two beadlock grooves 2 14991 4 Position the beadlock centering it between the tire beads 5 Lubricate the inner edge of the beadlock wheel and tire beads with tire soap to aid installation of the wheel Enhanced Mobility Package 3 24 Tires and Wheels Suspension Enhanced Mobility Package 6 Center the wheel air fitting with one of the grooves in the beadlock and press inner wheel into tire Notice Refer to Fastener Notice in Cautions and Notices 7 Install the air valve into the if a rubber valve is used install by pulling into position if a metal valve is used apply Loctite to the threads of the air valve Install it into the wheel and tighten Tighten Tighten the valve nut to 7 8 Nem 5 6 Ib ft 8 Apply the color indicator washer that matches the pressure sensor to the air valve or mark with paint 9 Onthe outer wheel apply a small amount of run flat lubricant to the O ring groove and install the O ring Remove excess of lubricant Important Ensure that both inner wheel sealing surfaces are completely free of any debris 10 Install the outer wheel into the tire Ensure that the air fitting is in line with one of the grooves 11 With the inner wheel studs facing up and install the wheel nuts by hand to a minimum of 4 threads Suspension Tires and Wheels 3 25 Important The specified torque patte
53. lacement Skid 00 2002 8 24 E Engine Control Module 6 10 Engine Control Module ECM Replacement 6 9 Engine Controls Description Air Filter Restriction Indicator 6 10 Engine Control Module 6 10 Repair Air Flow Adapter Replacement 6 9 Air Flow Meter Hose Replacement 6 6 Air Flow Meter 6 6 Engine Control Module ECM 6 9 Specifications ECM Calibration 49445 6 5 Engine Controls Specifications Fastener Tightening 6 5 Engine Electrical Repair Battery Reinforcement Bracket 6 4 Engine Electrical Specifications Fastener Tightening 6 3 Enhanced Mobility Package Vehicle 0 3 F Frame and Underbody Repair Front Skid Plate Replacement 8 22 Front Support Beam Replacement Skid Platey tent tentata 8 23 Fuel Tank Protection Cover Replacement 8 26 Rear Caliper Cover Replacement 8 27 Rear Frame Bracket Replacement Skid Plate ted nd 8 25 Rear Mud Flap Replacement
54. manual transmissions and transaxles including the fluid flow and circuit description information The technicians who understand the material in this manual and in the appropriate Dealer Service Bulletins better service the vehicle owners When this manual refers to a brand name a part number or a specific tool you may use an equivalent product in place of the recommended item All information illustrations and specifications in this manual are based on the latest product information available at the time of publication approval General Motors reserves the right to make changes at any time without notice Published by GM DEFENSE MILITARY TRUCKS General Motors Corporation Detroit Michigan 48265 2003 GENERAL MOTORS CORPORATION ALL RIGHTS RESERVED The information cutoff date is 07 01 04 LITHO IN U S A PART NO EMPSMO3 No part of this manual may be reproduced stored in any retrieval system or transmitted in any form or by any means including but not limited to electronic mechanical photocopying and recording without the prior written permission of General Motors Corporation This applies to all text illustrations and tables Preface 4 Preface Error and Suggestions Reporting If you find an error with this GM service manual supplement or if you have a suggestion about this GM service manual supplement we want to hear from you When calling be prepared with the following information e Your name e Your dealership s name M
55. nced Mobility Package Understanding Temperature Compensated Pressure Readings An important feature of the SmarTire Full Function Display system is that pressure deviation alerts are initiated from a comparison of the temperature compensated pressure to the measured tire pressure read by the sensor The reference pressure or cold pressure is the air pressure inside the tire inflated at room temperature 18 C 64 F to the vehicle manufacture s recommendation When a tire heats up the air pressure inside the tire can also be expected to increase For example a normal or required pressure at 64 F or 18 C may be 2 35 Bar 34 PSI and a normal pressure at 49 C 120 F may be 2 7 Bar 39 PSI Both pressure readings are correct at their respective temperatures The amount of deviation from the required pressure at any temperatures can be read by using the Pressure Deviation mode of this SmarTire product If at any time you are uncertain that the Actual Pressure reading on the display indicates the correct tire pressure switch to the Pressure Deviation 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 This value can then be used to correctly inflate the tire Suspension Tire Pressure Monitoring 3 51 Special Tools and Equipment Illustration Tool Number Description 15154 2
56. nder support areas Enhanced Mobility Package 8 18 Body Front End Body and Accessories BLANK Enhanced Mobility Package Body and Accessories Interior Trim 8 19 Interior Trim Repair Instructions Government Vehicle 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 4 new rivets 3 Enhanced Mobility Package 8 20 Interior Trim Body and Accessories BLANK Enhanced Mobility Package Body and Accessories Frame and Underbody 8 21 Frame and Underbody Specifications Fastener Tightening Specifications Specification Application Metric English Center Support Beam Bolts Pass Through 60 68 Nem 44 50 Ib ft Center Support Beam Bolts Threaded Hole 40 47 Nem 30 35 Ib ft Front Fuel Tank Cover Bolts 50 Nem 37 Ib ft Front Outer Fuel Tank Cover Bolts 29 Nem 21 Ib ft Front Skid Plate Bolts Front 21 Nem 15 Ib ft Front Skid Plate Bolts Rear 35 Nem 26 Ib ft Inner Fuel Tank Cover Bolts 29 Nem 21 Ib ft Rear Caliper Cover Nuts 45 Nem 33 Ib ft Rear Caliper Slide Bolts 180 Nem 133 Ib ft Rear Fender Support Bolt 25 Nem 18 Ib ft Rear Mud Flap Bolts 4 Nem 35 Ib in Rear Outer Fuel Tank Cover Bolts 85 Nem 63 Ib ft Rear Skid Plate Bolts 35 Nem 26 Ib ft Rear Support Beam Bolts 60 68 Nem 44 50 Ib ft Skid Plate Support Beam Bolts 35 Nem 26 Ib
57. ngine 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 Engine Control Module ECM The tires have been changed from the original equipment size to those adapted to off road usage The ECM must be reprogrammed using the ECM Calibration Chart of this manual Enhanced Mobility Package Body and Accessories Table of Contents 8 1 Section 8 Body and Accessories Instrument Panel Gages and Console etie erba oM VE 8 3 Specifications eren 8 3 Repair 444 4 8 4 Accessory Switch Panel Replacement 8 4 Description and Operation 8 6 Instrument Panel and Gages Description 8 6 8 7 4 44222 2 1 8 7 Repair 4 8 8 Bumper Replacement Front 8 8 Description and Operation 8 12 8 12 Body Front End 22 42 8 13 Specifications Ier 8 13 Repair 8 14 Radiator Support Reinforcement Replacement Upper and Low
58. ning which could result in loose wheels or premature wheel failure This could cause an accident or injury e Use of damaged parts is very dangerous These parts can fail during inflation later handling or while on the vehicle You or someone else could receive serious or fatal injuries e Dirt and corrosion can prevent rim components from seating properly or cause a bead hang up tire bead not seating properly Assembling such components can lead to explosive separation resulting in serious or fatal injury Do notattempt to disassemble a wheel assembly while the tire is fully inflated Serious injury may result Tire and beadlock are brand and size matched for this application If a different tire brand or size is used then a different beadlock may be required Failure to match the components can result in damage to components and possible loss of vehicle control 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 Enhanced Mobility Package 3 20 Tires and Wheels Suspension 1498 Enhanced Mobility Package 4 Loosen all the nuts in a star pattern until all the nuts have been removed 5 Apply tire soap to the edge of the outer rim flange 6 Using tire spoon and a 7 16 in wide blade pry bar gently pr
59. ns include maximum vehicle speed of 93 mph 150 km h Enhanced Mobility Package 6 6 Engine Controls Engine Repair Procedures Air Flow Meter Replacement Removal Procedure 1 Remove the accessory panel Refer to Accessory Panel Replacement in Instrument Panel Gages and Console 2 Remove the screws 1 from the meter 2 3 Remove the meter 2 from the panel Installation Procedure 1 Install the meter 2 onto the panel 2 Install the cover onto the meter with screws 1 and secure 3 Install the accessory panel Refer to Accessory Panel Replacement in Instrument Panel Gages and Console Air Flow Meter Hose Replacement Removal Procedure Note routing position prior to removal of hose for installation 1 Remove the meter hose 2 from the tube adaptor 3 2 Remove the tube from the cup 1 Enhanced Mobility Package Engine Engine Controls 6 7 3 Remove the lower bolts 1 of the accessory panel 2 4 Pull the I P cluster bezel out at the portion covering the panel 5 Remove panel enough to gain access to the air hose 2 6 Remove the air hose 2 from the air flow meter 1 7 Remove the airflow hose grommet 1 from the bulkhead and remove hose 2 from the vehicle Enhanced Mobility Package Engine Engine Controls 6 8 Installation Procedure 1 Install the air hose 2 with the grommet 1 and secure the grommet into the bulkhead opening
60. nt procedure in Driveline 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 Procedure in Driveline Axle Refer to the Maintenance Schedule in the Owner s Manual for other items of maintenance Enhanced Mobility Package 0 8 Maintenance and Lubrication General Information BLANK Enhanced Mobility Package Suspension Table of Contents 3 1 Section 3 Suspension Front Suspension 3 3 Tire Pressure Monitoring 3 30 Specifications oo inert erred 3 3 2 4 3 30 Repair Instructions eere 3 4 Schematic and Routing Diagrams 3 31 Shock Absorber Replacement 3 4 Tire Pressure Monitoring System 3 31 Lower Jounce Control Arm Replacement 3 6 Component 3 33 Jounce Shock Absorber Replacement 3 8 Connector End 3 35 Description and Operation 3 9 Diagnostic Information and Procedures 3 36 Front Enhanced Suspension 3 9 Error Code E1 3 36 Front Shock Absorber D
61. o revert to normal mode Level 2 Slope Refer to the Tire Pressure Monitoring System Setting chart in Specifications Notice 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 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 4 Pressthe 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 Note Repeat steps 2 6 until the slope level is set for all axles desired 7 Press the SET button to exit 8 Press the SET button again to revert to normal mode Suspension Tire Pressure Monitoring 3 45 Learn Note This mode is used to add or remove transmitters from the system Learn Procedure W O Special Tool 1 Enter Level 2 Programming Mode 2 Press the MODE button to select the learn mode icon 3 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 4 Usethe TIRE button to scroll to the desired position The outline of the wheel position to be programmed will
62. obility Package 3 50 Tire Pressure Monitoring Suspension Description and Operation General Description Tire Pressure Monitoring 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 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 7 seconds e Every 15 minutes when the vehicle is parked and pressure drops to 124 Kpa 18 PSI or lower Note Each color on front indicator panel refers to a Transmitter with a corresponding washer color on the valve stem Color washer must stay with the corresponding color Transmitter during tire rotation Transmitter Location Transmitter Wheel Position Green Right Front Red Left Front Blue Right Rear Yellow Left Rear 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 Enha
63. of an assistant remove the spare tire 3 from the vehicle Installation Procedure With the aid of an assistant place the tire 3 into the carrier Install the retainer 2 Install the washer 1 and nut 4 Tighten Tighten the nut to allow a minimum of 5 visible threads on the stud Spare Tire Carrier Replacement Removal Procedure S 0 M st Remove the spare tire Refer to Spare Tire Replacement Remove the hex bolts 1 from the carrier Remove the torx bolts 2 from the carrier Remove the carrier 3 from the vehicle Suspension Tires and Wheels 3 27 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 Jack Mounting Bracket Replacement Removal Procedure Remove 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 PONS 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 Nem 39 Ib ft 3 Install the lower nut 3
64. or Display Replacement Removal Procedure 1 2 3 Remove the accessory panel Refer to Accessory Panel Replacement in Instrument Panel Gages and Console Remove the nuts 1 and washers Remove the display from the panel Remove the display cable from the receiver Enhanced Mobility Package 3 38 Tire Pressure Monitorin Suspension Enhanced Mobility Package 15118 Installation Procedure 1 Route the display harness through the opening in the panel Install the display into the panel Install the washers and nuts 1 Install the accessory panel Refer to Accessory Panel Replacement in Instrument Panel Gages and Console Install the display cable into the receiver Pressure Transmitter Replacement Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices Raise and support the vehicle Remove the affected wheel Refer to Tire and Wheel Removal and Installation in the C K Truck Service Manual Remove the pressure transmitter sensor assembly Refer to Tire Mounting and Dismounting Procedure in Tires and Wheels Separate the transmitter sensor from the bracket Inspect all parts and replace as needed Suspension Tire Pressure Monitoring 3 39 Installation Procedure 1 Install the transmitter sensor into the bracket 15118 2 Install the pressure transmitter sensor assembly Refer to Tire Mounting and Dismounting Procedure in Tires and Wheels Notic
65. oring 3 47 Programming Procedure 1 10 11 Enter Level 2 Programming Mode of the Full Function Display by pressing the SET button for 5 seconds until SL can be seen in the display Press the MODE button to select learn mode which is indicated by a head with a question mark icon Press the TIRE button to display the ten 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 Front Right tire will be flashing Use the LF wand to activate the sensor from the Front Right tire When the sensor is activated and the Learn operation is successful the outline of the tire is filled in and the receiver will issue a chirping sound The red LED on the FFD will also light up Press the TIRE button to move to the Front Left tire and activate the sensor in this position Press the TIRE button 5 times to move to the Rear Right tire and activate the sensor in this position Press the TIRE button to move to the Rear Left tire and activate the sensor in this position Once all 4 positions have been Learn press the SET button to store the information The FFD will blink and the receiver will issue an audible tone to signify success 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 this happens press the Tire
66. r No Pin Wire Circuit Function Colour No 1 RED EM Battery Positive Voltage A C EN ____ Not Used 2 BLK Zu Ground D RED Battery Positive Volt 3 4 EE T Not Used PESE E up mE Not Used BLK E Ground Enhanced Mobility Package 3 36 Tire Pressure Monitoring Suspension Diagnostic Information and Procedures Error Code E1 Condition for Setting the Error This error may occur in certain vehicles where the receiver unit is powered even when the ignition is turned off Other possible causes may be broken tire sensors or a malfunctioning Receiver unit Mismatches in tire sensor ID may also cause this problem Error Code on Display Component Failing Fault Action s E1 Sensor s Not Transmitting If no transmission received within 5 Receiver RF Section Malfunction Minutes of driving contact dealer Error Code E2 Conditions for Setting the Error This error indicates that there is a problem with the data in the Receiver and on Display units Causes of this error can include e Corrupted custom profile e Corrupted factory profile The following may help identify the problem better Power the unit OFF and ON If the error has cleared Operating with the incorrect settings Contact dealer If error persists Receiver or Display may have to be replaced Error Code on Display Component Failing Fault Action s E2 Receiver EEPROM Fault Contact dealer and or Display Er
67. rn must be followed to prevent damage or improper sealing 12 Using the torque pattern tighten the nuts Tighten Tighten the wheel nuts first pass to 81 Nem 60 Ib ft Tighten the wheel nuts second pass to 102 108 Nem 75 80 Ib ft Important Retorque wheel nuts in a star pattern at 80 161 KH 50 100 MI and 8047 KH 5 000 MI thereafter retorque to 102 108 Nem 75 80 Ib ft Caution Inflating a tire with a hand held air chuck is dangerous You can be seriously injured 13 Place the tire in an approved inflation safety cage and inflate to 206 KPA 30 PSI 14 Check the tire bead seating for space 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 15 Inflate 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 7 Kpa 1 Psi the tire is acceptable for use 16 Dynamically balance the tire using a maximum balance weight of 6 oz per side Refer to Tire and Wheel Balancing Off Vehicle in the C K Truck Service Manual Enhanced Mobility Package 3 26 Tires and Wheels Suspension Enhanced Mobility Package Spare Tire Replacement Removal Procedure Remove the nut 4 and washer 1 Remove the spare tire retainer 2 With the aid
68. rocedure Notice The filter arrow must point toward the axle vent pipe 1 Install the filter 1 by pushing on the hoses 2 2 Remove safety stands 3 Lower the vehicle Enhanced Mobility Package Rear Drive Axle Description and Operation Rear Axle Vent Tube Filter Description The rear axle is specially equipped with a vent tube filter to protect the axle from contaminants found in the off road environment It is attached to a hose with a vented cap at the end The rear axle vent filter is mounted near the jounce bumper and 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 Periodic Maintenance Inspections in Maintenance and Lubrication in the Enhanced Mobility Package Owner s Manual Supplement Enhanced Mobility Package Driveline Axle 4 6 Driveline Axle Transfer Case 4 7 Transfer Case Repair Instructions Transfer Case Vent Tube Filter Replacement Removal Procedure Note The filter is located on the left side of the vehicle E Caution Refer to Vehicle Lifting Caution in Cautions and Notices 1 Raise and support the vehicle 2 Remove the hoses 2 holding the filter 1 3 Remove the filter and discard 4 Inspect the hoses and reducers for damage or wear Replace as needed If replacing the hose the length of the new hose must match the length of the old hose Installation
69. ror Code E3 Condition for Setting the Error These errors will usually represent an internal fault Try powering the unit OFF and ON to clear these errors If these errors continuously occur the unit may have to be replaced Error Code on Display Component Failing Fault Action s E3 Receiver Oscillator Fault Contact dealer and or Display Error Code E4 Condition for Setting the Error These errors will usually represent an internal fault Try powering the unit OFF and ON to clear these errors If these errors continuously occur the unit may have to be replaced Error Code on Display Component Failing Fault Action s E4 Receiver Internal Bus Fault Contact dealer and or Display Enhanced Mobility Package Suspension Tire Pressure Monitoring 3 37 Repair Procedures Receiver Replacement Removal Procedure So NE Remove the I P Knee Bolster Panel Disconnect the power cable 3 from the receiver Disconnect the display cable 1 from the receiver Using a flat bladed tool carefully cut through the two sided tape to release the receiver 2 Installation Procedure 1 zo Clean off any two sided tape remaining on the knee bolster panel Install the receiver 2 onto the panel in the same position as removed using two sided tape Connect the display cable 1 into the receiver Connect the power cable 3 into the receiver Install the I P knee bolster panel Monit
70. rucks MC 482 A19 A24 100 GM Renaissance Center P O Box 100 Detroit MI 48265 1000 Preface SERVICE MANUAL SUPPLEMENT COMMENT FORM Preface 5 Use this form to advise us of any errors you might find in this manual We also welcome suggestions for improving this Service Manual Supplement Service Manual s that have the error Page number s that have the error Graphic number s that have the error VIN if available or model and applicable options Describe in detail the error found or the suggestion s Attach additional pages if necessary From Organization Name City Town Name of Person Submitting This Comment Form Signature Mail To GM Defense Mail Code 482 A19 A24 100 GM Renaissance Center P O Box 100 Detroit MI 48265 1000 USA Attention ILS Manager Fleet and Commercial Preface 6 Preface BLANK Table of Contents Table of Contents 1 Table of Contents Preface General Information General 0 0 3 Maintenance and Lubrication 0 7 Suspension Front Suspension aa 3 3 Rear 3 11 Tires and Wheels 3 17 Tire Pressure 3 30 Driveline Axle Fron
71. settings above when required To Change the Cold Inflation Pressure settings for each axle 1 Enter Level 1 Programming Mode by pressing the SET button for 2 seconds 2 Pressthe 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 Note Repeat programming steps 2 6 until Cold Inflation Pressure levels are set for all axles as desired 7 Press the SET button to exit To Change the Low Pressure Warning setting for each axle Refer to the Tire Pressure Chart in Specifications 1 Enter Level 1 Programming Mode by pressing the SET button for 2 seconds 2 Toenter 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 4 Pressthe MODE button to view the current value Press the TIRE button to increase the value 6 Press the MODE button to decrease the value Suspension Tire Pressure Monitoring 3 49 T Press the SET button to save when the desired value is reached Note Repeat programming steps 3 7 until Low Pressure Warning levels are set for all axles as desired 8 Press the SET button to exit Enhanced M
72. t Drive 0 4 3 Rear Drive Axle nocte eis 4 5 Transfer Case i eR Ec TR Dit ues 4 8 Engine Engine Electrical oret 6 3 Engine Controls iiine 6 5 Body and Accessories Instrument Panel Gages and Console 8 3 56 ote a 8 7 Body Front End asiento 8 13 Interior TEE oro itc o ates 8 19 Frame and 8 21 INDEX einen INDEX 1 Enhanced Mobility Package 2 Table of Contents Table of Contents BLANK Enhanced Mobility Package General Information General Information 0 1 Section 0 General Information General Information 0 3 Government Data 0 5 Vehicle Identification 222 4 0 3 Maintenance and Lubrication 0 7 Equipment Options sess 0 4 Maintenance eire ree 0 7 Commercial Utility Cargo Vehicle EMP Owner Checks and 0 7 Specifications Options 0 4 Periodic Maintenance Inspection 0 7 EDI 0 5 Enhanced Mobility Package 0 2 General Information General Information BLANK Enhanced Mobility Package General Information General Information Vehicle Identification T
73. torin Suspension Enhanced Mobility Package High Temperature Alert Note This function changes the high temperature alert threshold Factory Default 80 C 176 F 1 Enter Level 1 Programming Mode 2 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 Pressthe TIRE button to increase the value 5 Press the MODE button to decrease the value 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 Metric or Imperial Measurement Selection Note Use this mode to select the combination of pressure and temperature units Unit Combinations Bar C Bar F PSI C PSI F Programming Steps 1 Enter Level 1 Programming Mode 2 Toenter 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 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 Suspension Tire Pressure Monitoring 3 43
74. y the outer flange away from the tire bead in 3 points as follows Install the tire spoon 1 between the flange and the tire and pull down until the spoon is horizontal with the working surface e 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 e Using the tire spoon 2 and pry bar 3 at intervals of 45 work around the wheel and tire e Remove the outer wheel from the tire and remove the O ring and discard Note Ensure that the wheel half is placed with the O ring side facing up to avoid scratching the surface Suspension Tires and Wheels 3 21 7 Flip the tire assembly over and apply tire soap to the inner flange 8 Using the pry bar and tire spoon gently pry the inner flange from the tire bead as follows Using the tire spoon 1 between the flange and tire push the tire spoon down until it is horizontal to the working surface to lift the wheel flange up e Using the pry bar between the flange and tire push the tire bead down The pry bar will push the tire 1 down and off of the 5 bead seat Using the prybar 1 and tire spoon 2 work your way around the tire at intervals of 45 e Remove the inner wheel half from the tire Note Ensure that the wheel half is placed with the O ring side facing up to avoid scratching the surface 1498 9 Locate the air pressure sensor 1 and compress the beadlock

2003 EMP Service Manual Supplement

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