15045.11 GM Braking Systems

8/15/2019 15045.11 GM Braking Systems

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Instructor’s Guide

Course Component Number: 15045.11H

©2006 General Motors Corporation. All Rights Reserved. 15045.11H 08/06

GM BrakingSystems


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ServiceTechnicalCollege GM Braking Systems

Course #15045.11H

GM Braking Systems

Length: One Day

Prerequisites: Course #18043.01W (Electrical/Stage 1), Course#18043.02W (Electrical/Stage 2), Course #18043.03W(Electrical/Stage 3), Course #16048.15W (TECH 2), Course#10041.00W (SI Overview) and Courses #15045.11W (GMBraking Systems CBT), #15045.11D1 and D2 (GM Braking

Systems IDL sessions 1 and 2).

Description: This course consists of exercises related to the diagnosis andrepair of foundation brakes and ABS systems that areperformed by students working in groups.

Divisions: All

Classification: For the technician experienced in brake system service.

Class Size: Ten


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Table of contents

Topic PageObjectives.................................................................................................. iii

Course Agenda – Morning..........................................................................v

Course Agenda – Afternoon ......................................................................vi

Course Materials ....................................................................................... ix

Instructor Preparation............................................................................... xii

Required Student Skills .......................................................................... xiv

Morning Activities .......................................................................................1

Afternoon Activities.................................................................................. 33

Master copies of desk exercise worksheets:


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Objectives

Upon completion of this course, the technician will be able to perform diagnostic andrepair procedures on foundation brakes and anti-lock brake systems (ABS).

The technician will gain experience using the Service Information Web site and otherfundamental tools necessary to complete the task.

Objective Skills

Service Information (SI)

SI-1: Read owner's manual descriptions of system operationSI-2: Read service manual descriptions of system operation

SI-3: Study electrical schematic diagrams to determine system operation

SI-4: Follow published procedures for system diagnosis

SI-5: Follow published procedures for system repair

Tools (TO)

TO-1: Use a TECH 2 scan tool to view and clear DTCs, view diagnostic data, and

perform special testsTO-2: Use a digital multimeter (DMM) to make voltage, amperage, and resistance

measurements of circuits and components

TO-3: Use brake diagnostic tools to check component functions

TO-4: Use brake repair tools to make component adjustments

TO-5: Use brake service tools to disassemble and reassemble disc and drum brakeassemblies

TO-6: Use brake pipe fabrication tools to make a replacement brake pipe

TO-7: Use brake measurement tools to check drum dimensions

TO-8: Use brake measurement tools to check disc dimensions

TO-9: Use a brake lathe to refinish a rotor


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Objectives (continued)

Diagnostic Strategy (DS)

DS-1: Use an efficient strategy to diagnose a current fault related to a stored DTC,with published procedures to follow

DS-2: Use an efficient strategy to diagnose a current fault related to a symptomwithout a stored DTC, with published procedures to follow

DS-3: Use an efficient strategy to diagnose an intermittent fault related to a storedDTC or symptom, with published procedures to follow

DS-4: Develop an efficient strategy to diagnose a fault related to a symptom, with nopublished procedures to follow

DS-5: Use an efficient strategy to determine that a system operates as designed

Technical Knowledge (TK)

TK-1: Use technical knowledge of foundation brakes basics that has been gainedfrom previous learning and work experience

TK-2: Use technical knowledge of electrical circuit basics that has been gained fromprevious learning and work experience

TK-3: Use technical knowledge of brake light circuits that has been gained fromprevious learning and work experience

TK-4: Use technical knowledge of basic operation of ABS, traction control system(TCS), and vehicle stability enhancement system (VSES) gained from previouslearning and work experience

TK-5: Use technical knowledge of ABS/TCS/VSES input and output circuits thathas been gained from previous learning and work experience


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Course Agenda

Morning Session:

Station Description Fault/Set-up ObjectiveSkill

Classroom

Workstation 1:

Diagnostic procedure forHall Effect wheel speedsensor used on the Malibu.

Describe operation of HallEffect sensor / DigitalWSS and performworksheet.

TO-1, TO-2,DS-5, TK-1,TK-2, TK-4,TK-5, SI-2,SI-3, SI-4

Vehicle:

2007Chevrolet

Malibu

Workstation 2:

Diagnose customerconcern: Stabilty messagein the DIC Traction controllight ON.

Index the steering wheelposition sensor 180degrees from originalposition.

SI-1, SI-2, SI-4, SI-5, TO-3,

DS-2,TK-1

Vehicle:

2007 Saab9-7x

Workstation 3:

Diagnose customerconcern: Amber ABS andTraction control light on.

Pull wake up circuit 5727from underhood fuse blockto simulate open circuit.No communication withEBCM.

SI-2, SI-3, SI-4, SI-5, TO-1,TO-2, DS-1,TK-2, TK-4

Vehicle:

2007Buick

Lucerne/Cadillac

DTSWorkstation 4:

Diagnose customerconcern: Brake pulsation(rotor with excessive lateralrunout fault).

Machine the rotor toexhibit lateral runout.

SI-4, SI-5,TO-3, TO-4

DS-2TK-1

Desk /Mock-up

Workstation 5:

Understand componentoperation and assembly of

Duo Servo andLeading/Trailing edge rearbrake assembies.

Disassemble, inspect andreassemble Duo Servo

and Leading/Trailing edgerear brake assemblies.

SI-5, TO-5,TK-1

Mock-up:


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Course Agenda

Afternoon Session:

Station Description Fault/Set-up Objective Skill Classroom

Workstation 6:

Diagnose customerconcern: ABS light is ON(EBCM communicationcircuit fault U2108).

Create open circuit in thepower feed to the EBCMin order to create a nocommunication concern.

SI-2, SI-3, SI-4,SI-5, TO-1,TO-2, DS-1,TK-2, TK-4

Vehicle:

2007Chevrolet

Malibu

Workstation 7:

Diagnose customer

concern: ABS light is ON(wheel speed sensor signalmissing fault).

Create an excessive air

gap for the right frontwheel speed sensor sothat it produces a lowvoltage signal.

SI-1, SI-2, SI-3,

SI-4 TO-1, TO-2 DS-2, DS-4TK-4, TK-5

Vehicle:

2007 Saab

9-7x

Workstation 8:

Diagnose customerconcern: Traction controllight with Service Stabilitymessage in messagecenter.

Create on open in the lowreferance circuit 719.Trac light and VSESmessage in DIC, nocodes present.

SI-1, SI-2, SI-3,SI-4

TO-1, TO-2DS-2, DS-4TK-4, TK-5

Vehicle:

2007Buick

Lucerne/Cadillac

DTS

Workstation 9:

Make a replacement brakepipe with bends and twotypes of flares.

Locate service brakepipe, bending and flaringtools on a workbench,along with a sample ofthe original line.

SI-5, TO-6, TK-1

Bench:

Brake pipewith

bendingand flaring

tools

Workstation 10:

Measure brake drum androtor surfaces for excessive

wear.Measure thicknessvariation.

Qualify brake lathe, refinishbrake rotor.

Locate several brakedrums and rotors with

various states of wearand a drum micrometeron a workbench Measuredrum and rotor, qualifythe brake lathe and turnrotor.

SI-4, SI-5TO-9

TK-1

Bench:

Disc brakerotors and

brake lathe


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Course Materials

Student Materials

10 Clip Boards

10 Pencils

10 Highlight Markers

Vehicle List

1 2007 Chevrolet Malibu with ABS

1 2007 Saab 9-7x with ABS/TCS/VSES (w/JL4)

1 2007 Buick Lucerne with ABS/TCS/VSES (w/JL4)

OR1 2007 Cadillac DTS with ABS/TCS/VSES (w/JL4)

Tool List

1 J 42450-A Wheel Hub Cleaning Kit

1 J 41013 Wheel Hub Resurfacing Kit

1 J 45101-100 Conical Retaining Washers

1 J 39544 Torque Socket

4 J 35616-A GM Terminal Test Kit

1 J 38125-B Terminal Repair Kit

4 J 39200 Digital Multimeter1 J 39700 Universal Pinout Box

1 J 39700-300 Cable Adapter

4 J 36169-A Fused Jumper Wire

1 J 34142-B Unpowered Test Light

1 J 45405-A Flaring Kit

1 J 29840 Brake Spring Remover and Installer

1 J 8049 Brake Spring Remover and Installer

1 J 8057 Brake Spring Pliers

1 J 21777-A Brake Drum/Shoe Clearance Gauge1 BA804, 03, 06, 09 – Brake Align Shim 2004 Malibu


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Course Materials

Hand Tools

1 Set of Assorted Screwdrivers1 Set of Assorted Pliers

1 1/4” Drive Metric Socket Set (5 – 10 mm), including Torx Bits and Sockets

1 3/8” Drive Metric Socket Set (8 – 18 mm), including Torx Bits and Sockets

1 1/2” Drive Metric Socket Set (10 – 24 mm)

2 Pair of Safety Glasses

3 Fender Cover Set

3 Vehicle Exhaust Hose Set

1 C-Clamp (12” capacity)

2 Dial Indicator Kit with Vise Grip Base and Flexible Locking Arm2 Disc Brake Micrometer Set (0” – 1” range & 1” – 2” range with Pointed Tips)

2 Brake Drum Micrometer Set (14” maximum diameter capacity)

1 1/2" Drive Torque Wrench (0 – 200 lb ft)

1 1/2" Drive Air Impact Gun

1 Brake Pipe Cutting Tool

1 Brake Pipe Bending Tool

1 Vacuum Gauge

Equipment List3 TECH 2 Scan Tool

5 Techline Terminal with Service Information

3 Battery Charger

8 Jack Stand

2 Floor Jack

2 Creeper

1 Brake Lathe, with User's Manual, Accessories, Replacement Cutting Bits and aNon-Directional Finishing Tool


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Course Materials

Component List

1 Brake Align Kit, including Videotape (Workstation 4)

1 Tube of High Temperature Silicone Brake Lubricant (Workstation 5)

1 Sample Brake Pipe, with Bends and Fittings (Workstation 9)

1 Supply of Replacement Brake Pipe for Cutting/Bending/Flaring (Workstation 9)

1 Supply of ISO and Double Flare Fitting Nuts (Workstation 9)

1 Supply of 3 Brake Drums in Various States of Wear (Workstation 10)

1 Supply of 4 Disc Brake Rotors for Refinishing (Workstation 10)

Duo Servo

1 Backing Plate – 18015444

3 Bolt – 09440954

3 Nut – 11516074

3 Washer – 00331247

1 Guide – 05460399

1 Spring Kit – 18012261

1 Spring Kit – 18002399

1 Adjuster Kit – 18034434


1 Bolt Kit – 18012264

1 Shoe Kit – 18009539

1 Drum – 15693455

1 Wheel Cylinder – 18017570

1 Lever Kit – 00458483


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Component List (continued)

Advanced Leading/Trailing 2006 Chevrolet Malibu

1 Drum – 88957254

1 Adjuster Spring And Actuator – 18020402

1 Lever Kit – 18029866

1 Spring – 18029953

1 Backing Plate – 18025172


1 Shoe Kit – 18029865

1 Wheel Cylinder – 18029868

2004 Chevrolet Malibu/LRO Mock-up

1 Knuckle – 21995733

1 Rotor – 22705302

1 Hub – 22706967

4 Bolt – 11588890

5 Wheel Nut – 09594683


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Instructor Preparation

To prepare to deliver this course, do the following:

• Obtain and read the Instructor’s Guide.

• Organize the classroom and obtain the materials (see Course Materials for details).

• Obtain owner’s manuals for each classroom vehicle.

• Set up Techline terminals so that students can use Service Information.

• Set up each of the Workstations and prepare each exercise, following the directions inthe Instructor’s Guide.

• Complete each Workstation as a student and make adjustments as necessary.

• Make 10 copies of each of the work orders for the Workstations and related student

materials and keep them in the hanging file storage box.• Make one copy of the Required Student Skills form to keep track of student progress

as the course exercises occur.


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Instructor PreparationGeneral Class Notes

1. Workstation 2 – Prepare the 2007 Saab 9-7x:• Remove kick panel

• Disconnect SWPS

• Disengage SWPS from column and rotate outer housing 180 degrees

• Slide SWPS back into position

• Verify code sets with TECH 2

2. Workstation 3 – Prepare the 2007 Buick Lucerne or 2007 Cadillac DTS:

• Remove the underhood fuse block by releasing the 4 tabs located on theside of the box.

• Use a 7mm socket to unseat C3• Use 12094429 terminal removal tool to remove circuit 5727 OG/YE pin 34

• Tape back and reinstall connector and box back into position

• Use TECH 2 to ensure ‘No communication’ condition is present

3. Workstation 4 – Prepare the 2004 Malibu mock-up hub assembly by machining arotor to have LRO. Place a thin piece of paper between bell clamp and rotor,then machine rotor and measure to ensure LRO is present but not excessive.Use corrective shim BA804-03, 06, 09

4. Workstation 6 – Prepare the 2004 Chevrolet Malibu EBCM ‘No communication’:• Remove the Ignition 1 voltage, circuit 139, from EBCM connector

• Tape the circuit into the harness and install a pink dummy wire in place ofthe Ignition 1 voltage cavity.


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5. Workstation 7 – Prepare the 2007 Saab 9-7x:

• Raise the vehicle and create an excessive air gap in the right front wheelspeed sensor.

• Reinstall the wheel speed sensor and wheel assembly.

6. Workstation 8 – Prepare the 2007 Buick Lucerne or 2007 Cadillac DTS

• Disconnect C111 from driver side strut tower

• Remove circuit 719 PU pin A2

• Install dummy circuit back into pin A2

• Reinstall C111

• Verify with TECH 2

7. Workstation 9 – Prepare the brake pipe fabrication workbench:

• Fabricate a sample brake pipe that has bends, a double-flare fitting and anISO-flare fitting

• Obtain lengths of brake pipe and prepare shorter lengths that are longerthan required to fabricate brake pipes that match the sample

8. Workstation 10 – Prepare the brake drum/rotor measurement/lathe workbench:

• Obtain at least 2 brake drums and rotors with a variety of braking surfacewear conditions from various vehicles

• Attach a tag to each brake drum and rotor with vehicle year/make/modelinformation so students can research SI to obtain the measurement

specifications• Measure each drum and rotor, make notes about its condition as a

reference

• Student will qualify lathe and resurface one rotor


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Required Student Skills - Page 1 of 2Hands-On Course #15045.11H

SKILLS REQUIRED

FOR MASTERY

W O R K S T A T I O N :

R E M E D I A T I O N :

S T U D E N T :_____________________

___

S T U D E N T :_____________________

___

S T U D E N T :_____________________

___

S T U D E N T :_____________________

___

S T U D E N T :_____________________

___

S T U D E N T :________________________

S T U D E N T :________________________

S T U D E N T :________________________

S T U D E N T :_____________________

___

S T U D E N T :_____________________

___

Use Service Information:

1 Owner's manualdescriptions

Instructor

2 Service manual descriptions Appliesto all WS

10041.00W50240.14T1

3 Electrical schematicdiagrams

1, 3, 6, 818043.01W50240.14T1

4 Diagnostic and repairprocedures

1, 2, 3, 4,5, 6, 7, 8,

9, 1010041.00W

Use Tools:

1 TECH 2 scan tool1, 3, 6,

7, 816048.15W16048.20D

2 Digital multimeter1, 3, 6, 7,

818043.01W50240.10T1

3 Brake diagnostic tools 2, 4, 1015045.11W15045.11D

4 Brake repair tools2, 4, 5,9, 10

15045.11W15045.11D

5 Brake service tools2, 4, 5,

1015045.11W15045.11D

6 Brake pipe bending/flaringtools

215045.11W15045.11D

7 Drum brake measuring tools 10 15045.11W15045.11D

8 Disc brake measuring tools 1015045.11W15045.11D

9 Brake lathe 1015045.11W15045.11D

Note: There is no test with this course. Observe and evaluate competency during the workstationrotations. Each student must demonstrate the key skills applicable to each workstation.


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Required Student Skills - Page 2 of 2Hands-On Course #15045.11H

SKILLS REQUIRED

FOR MASTERY

W

O R K S T A T I O N :

R

E M E D I A T I O N :

S

T U D E N T :________________________

S

T U D E N T :________________________

S

T U D E N T :________________________

S

T U D E N T :________________________

S

T U D E N T :________________________

S

T U D E N T :______________________

__

S

T U D E N T :______________________

__

S

T U D E N T :______________________

__

S

T U D E N T :________________________

S

T U D E N T :________________________

Use an efficient Diagnostic Strategy:

1 Current faults with DTCs,using published procedures

3, 6 10041.00W

2 Current faults without DTCs,using published procedures

8 10041.00W

3 Intermittent faults withDTCs, using publishedprocedures

7 10041.00W

4 Hard faults without DTCs,using own procedures

2 10041.00W

Use Technical Knowledge:

1 Foundation brakes basics1, 2,5, 9,10

15045.11W15045.11D

2 Electrical circuit basics1, 3,6, 7,

8

18043.01W50240.10T1

3 BRAKE light circuits3, 6,7, 8

15045.11W15045.11D

4 ABS/TCS basic operation1, 3,6, 7,

8

15045.11W15045.11D

5 ABS/TCS input/outputcircuits

1, 3,

6, 7,8

15045.11W15045.11D

Note: There is no test with this course. Observe and evaluate competency during the workstationrotations. Each student must demonstrate the key skills applicable to each workstation.


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InstructorWorkstation

Reference


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Day 1 Morning Activities

Overview

30 minutes before session begins

Preparation of Workstations:

• Set up Workstations 1, 2, 3, 4, and 5 (refer to set-up details on the pagesthat follow)

• Note that variations for each workstation may be available

15 minutes

Course Introduction:

• Course length

• Course objectives

• Course evaluation

• Course activities

Session Introduction:

• Workstations 1, 2, 3, 4, and 5

• Each student must demonstrate key skills at each workstation

• Each workstation requires written documentation on work orders

150 minutes

Workstations:

• Student pairs rotate between workstations every 30 minutes

• Monitor work of student pairs (refer to expected technician path details onthe pages that follow)

• Use Required Student Skills form to record student achievement

30 minutes

Debrief Session:

• Highlights of Workstations 1, 2, 3, 4, and 5 (refer to the Debrief Session)


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Workstation 1

Objective After completing this workstation exercise, each student will be able to:

• Research Service Information

• Use DMM to measure voltage, current, or resistance

• Understand operation of the Hall Effect sensor

• Perform diagnoses on the Hall Effect sensor

Station Set-Up

Vehicle: 2007 Chevrolet Malibu

Symptom: Not required

Fault Set-up Time: Less than 5 minutes with vehicle area preparation completedprior to course

Fault Set-Up Steps:

1. Make 10 copies of each worksheet (master copies are located at the end ofthis guide). Note that each student is required to complete each of the twoworksheets.

2. Place vehicle on hoist.

3. Ensure to clear codes after each test. If codes are present, EBCM will go intodefault mode.

ComponentsNone

Tools

Instructor: None

Technician: • DMM

• 2 Fused jumper harness

• J 35616-A GM terminal test kit


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Workstation 1 – Page 12007 Chevrolet Malibu

Step Directions Yes No

1Install scan tool and check for DTCs in the brake subsystem.

Are there any DTC present?

GO TOStep 2

GO TOStep 3

2Clear all DTCs in related modules.

Do any DTCs reset?

SeeDTCChart

GO TOStep 3

3

1. Disconnect the wheel speed sensor harness connector.2. With the ignition ON, measure the wheel speed reference

voltage at the harness connector.3. Does the wheel speed reference voltage measure

greater than the specified value?Measured Voltage__________ Spec. 8 V

GO TOStep 7

GO TOStep 4

4

Test the wheel speed sensor supply voltage circuit for anopen or a short to ground. If DTCs are set for front and rearwheels on the same side of the vehicle, test for a short toground on both sensor supply voltage circuits. Refer toCircuit Testing and Wiring Repairs in Wiring Systems.

Did you find and correct the condition?

GO TOStep 7

GO TOStep 5

5

Test the wheel speed sensor signal circuit for an open, short

to ground or a short to voltage. Refer to Circuit Testing andWiring Repairs in Wiring Systems.


GO TOStep 7

GO TOStep 6

6

Inspect for poor connections at the harness connector of thewheel speed sensor and EBCM. Refer to Testing forIntermittent and Poor Connections and Connector Repairs inWiring Systems.


GO TOStep 7

GO TOStep 9

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Workstation 1 – Page 2

7

Important

If the DMM is not connected properly, a DTC can set. Nowheel speed DTCs should be set during this diagnostic.

1. Turn OFF the ignition.2. Disconnect the wheel speed sensor harness connector.3. Complete the wheel speed reference voltage circuit by

connecting a 3-amp fused jumper wire between theconnector harness and the wheel speed sensor.

4. Connect a DMM between the harness connector andthe wheel speed sensor to measure amperage of thewheel speed sensor signal circuit.

5. Turn ON the ignition.6. Rotate the wheel very slowly.

Does the amperage toggle low to high for the given specifiedvalues?

Measured Amperage Hi __________ Low ___________

Spec. Hi 11 -16 ma Low 4-8 ma

GO TOStep 8

GO TOStep 10

Step Directions Yes No

8

Important: If the DMM is not connected properly, a DTCcan set. No wheel speed DTCs should be set during thisdiagnostic.

With the DMM still connected, spin the wheel as fast aspossible.

Does the amperage read steady between the specified value?

Measured Amperage ____________

Spec. 7.5 -12 ma

GO TOStep 11

GO TOStep 10

9

Replace the EBCM. Refer to Electronic Brake Control Module(EBCM) Replacement .

Did you complete the repair?

GO TOStep 11

GO TOStep 11

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Workstation 1 – Page 3

10

1. Replace the wheel speed sensor. Refer to WheelBearing/Hub Replacement - Front in Front Suspension

or Wheel Bearing/Hub Replacement - Rear in RearSuspension.

2. Use the scan tool in order to clear the DTCs.3. Cycle the ignition from OFF to ON.

Does the scan tool indicate that a wheel speed DTC with asymptom byte of 00 is currently set?

GO TOStep 1

GO TOStep 11

11

2006 Malibu DTC C0035-C0051 chart has ___________symptom descriptors?

List the number and define the descriptor below:

DTCSymptom

DTC Symptom Descriptor

The wheel speed sensors 2 wired circuited inputs to theEBCM?

GO TOStep 12

GO TOStep 11

12

For DTC C0035 –C0050 18 to set the following conditionsexist:

*__________________________________________

*__________________________________________

*__________________________________________

Must all conditions be present for DTC to set?

GO TOStep 13

GO TOStep 12

13

1. Reinstall the wheel speed connector to Wheel Bearing /Hub

2. Connect Scan tool and check for DTCs in the Brake

Sub System

Are there any DTCs present?

GO TOStep 14

ExerciseComplete

14

Clear all DTCs in related modules.

1. Recheck the Brake Sub System for DTCs

Do any DTCs reset?

GO TOStep 1

ExerciseComplete

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Workstation 1


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Workstation 2



• Understand how to take and use snapshots as a diagnostic guide

• Understand how to read and use electrical schematics

• Use strategy-based diagnostic principles to diagnose concern

• Use proper diagnostic tools to isolate the root cause of the customerconcern

Station Set-UpVehicle: 2007 Saab 9-7x

Symptom: Customer states that the traction control light is ON; “Stabilitrak Off“message appears in DIC.

Fault Set-up Time: Less than 5 minutes with vehicle preparation completed priorto course.

Fault Set-Up Steps:

1. Use TECH 2 to take snapshot of SWPS signal 1 and 2 and position A and Bfor later reference through TIS 2000. Note: If these values do not appear the

EBCM may need to be reprogrammed.2. Remove driver side kick panel.

3. Remove I-shaft bolt (15mm).

4. Disconnect the SWPS connector.

5. Remove SWPS retaining plate

6. Slide the SWPS forward, there is a tight tolerance between the sensor andshaft take care not to damage while walking it forward.

7. Rotate the outer shell one revolution ensuring that the inner portion does notrotate along with the outer shell.

8. Verify with TECH 2 that code C0455 sets. May need to start and rotatesteering wheel.

9. Take snapshot with TECH 2 after fault has set for reference later.


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Tools

Instructor:

Hand tools

Technician:

• TECH 2

• DMM

• Techline terminal with Service Information

• Test lead adapter kit J 35616


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Documentation (Expected Technician Path):

Verify concern

Stability message in the DICCode in EBCM C0455

Traction light ON

Perform Diagnostic Checks

Follow the Diagnostic Starting Point – Anti-lock Brake System Information

Follow the Diagnostic System Check – Vehicle chart:

Step 1: Perform visual inspections.

Step 2: The scan tool powers up.

Step 3: The scan tool communicates with the expected control modules.

Step 4: Power mode readings match switch positions.

Step 5: Engine cranks.

Step 6: Engine starts and idles.

Step 7: Scan tool does display DTC C0455.

Step 8: No

Step 9: No

Step 10: No

Step 11: Diagnostic Trouble Code (DTC) List - Vehicle

DTC C0455 (Doc ID# 1576342) Any of the following conditions may cause the DTC to set:

• The analog steering wheel position signal does not correlate with the digitalsteering wheel position signals

• When driven forward in a straight line, the centered steering angle differs bymore than 30 degrees from the centered steering angle when the sensors areinitialized

Step 1: Yes

Step 2: Yes, (may need to rotate steering wheel one revolution for the code to

reset)Step 3: If the scan tool does not display the parameter, the tech will need to usethe DMM to observe the voltage readings, 5v reference, and low reference. Backprobe sensor signal to determine voltage and rotate steering wheel position lock-to-lock taking note of voltages full right, center, and full left.

Note: Straight ahead position should indicate 2.5 volts but does not. Thisindicates steering wheel position is not centered properly.

http://service.gm.com/servlets/CellHandler?CellId=72795&RefDoc=1619715&evc=smhttp://service.gm.com/servlets/CellHandler?CellId=72795&RefDoc=1619715&evc=sm


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Workstation 2


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Instructor Notes:

______________________________________________________

______________________________________________________ ______________________________________________________

______________________________________________________

______________________________________________________

______________________________________________________


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Workstation 2


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Workstation 3


• Research Service Information using Lean Diagnostics

• Use strategy-based diagnostic principles to diagnose ‘no communication’concern

• Understand Power Mode Master

• Understand GMLAN diagnostics

• Use Description and Operation in SI as an aid in diagnosis

• Use TECH 2 to retrieve, view, and clear codes


Station Set-Up

Vehicle: 2007 Buick Lucerne / Cadillac DTS

Symptom: Customer states that the ABS and traction control light is ON.


Fault Set-Up Steps:

1. Remove underhood junction box by releasing the 4 hold down tangs on eachcorner.

2. Locate and remove C3 using a 7mm socket.

3. Locate and remove wake up circuit 5727 OG/YE pin 34 using 12094429removal tool.

4. Tape circuit back into harness, re-connect C3, and install fuse box back intoposition.

5. Use TECH 2 to verify code U0121.

ComponentsNone (wiring fault)


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Tools

Instructor: J12094429

Technician:

• TECH 2 scan tool

• J39200 digital multimeter

• J35616-A GM terminal test kit



Verify concern Operate the vehicle and observe that the ABS light is ON.


• Diagnostic Starting Point (Doc ID# 1404836)

• Diagnostic System Check – Vehicle (Doc ID# 1693593)

• Diagnostic Trouble Code (DTC) List – Vehicle (Doc ID# 1693609)

• U0100-U0299 (Doc ID# 1686315)

Instructor Notes:

______________________________________________________

______________________________________________________

_______________________________________________________


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Workstation 3


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Workstation 4



• Understand and know the difference in lateral runout and thicknessvariation and its effects

• Use proper tools to isolate and repair the customer concern

Station Set-Up

Vehicle: Mock-up

Symptom: Customer states that brakes pulsate when applied (service advisorverified customer concern with road test).

Fault Set-up Time: Less than 5 minutes with mock-up preparation completedprior to course.

Fault Set-Up Steps:

1. Number each wheel stud location on the hub and brake rotor using a marker.

2. Install a Brake Align correction plate between each rotor and the wheel hub tocause excessive rotor runout that is greater than 0.050 mm (0.002”). Use adial indicator to verify the presence of excessive runout. Note that a correction

plate is available in three sizes and can provide 0.003”, 0.006”, and 0.009”additional runout if installed to create this fault.

3. Secure each brake rotor to its hub using the conical washers and wheel lugnuts.

Note: You’ll need to load the Brake Align Installation CD onto the computerdesktop to allow student review of the brake align installation procedure (8 minutesin length). Simultaneously press the ‘Ctrl’ and ‘Enter’ keys to show the video in fullscreen mode.

Components• Brake Align correction plates BA 804, -03, -06, -09 (0.003”, 0.006”, and

0.009” correction sizes)


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Tools

Instructor:

• Hand tools

• Dial indicator with vise grip base and flexible locking arm

Technician:

• Hand tools

• Brake Align correction plate kit

• Dial indicator with vise grip base and flexible locking arm



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Verify concern

Study Service Information documents #1671790 (Front Brake Pulsation #00-05-22-002F) and #777349 Info-Brake Align System #01-05-23-001)

View the Brake Align Installation Procedure videotape (8 minutes in length),including the following key points:

• Clean the rotor contact flange on the hub

• Mount the rotor on the hub, using special conical washers and wheel lugnuts

• Use a dial indicator to determine the low and high spot of lateral runout(maximum allowable runout is 0.002”)

• Mark the high spot on the rotor and hub

• Remove the rotor and install a correction plate with its notch aligned withthe mark on the hub (correction plates are available in sizes to correct0.003”, 0.006”, and 0.009” runout)

• Reinstall the rotor and check that lateral runout is within specification


Follow the recommended procedures of the Service Information document#1510324 (Front Brake Pulsation #00-05-23-002D):

•

Inspect the brake pads for correct material application• Check the rotors for thickness and runout

• Recommend the installation of a correction plate for each rotor, includingdetails of which plate to install and how to locate it on the wheel hub duringinstallation

Instructor Notes:

______________________________________________________

______________________________________________________

______________________________________________________

______________________________________________________


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Workstation 4


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Workstation 5

Objective

After completing this workstation exercise, each student will be able to:


• Understand the differences in rear drum brake assemblies

• Properly use brake tools

• Identify correct installation of components

Station Set-Up

Vehicle: Mock-up

Symptom: Disassemble, inspect, and reassemble the rear drum brakes, includingadjustments.

Fault Set-up Time: Less than 5 minutes with workbench preparation completedprior to course.

Fault Set-Up Steps:

1. Position the tools related to brake shoe replacement on workbench nearmock-up.

2. Obtain 2 brake drums from a variety of vehicles, with an assortment of surfaceconditions (grooves, excessive out-of-round, and excessive taper).

3. Place the brake drums, a drum micrometer set, and an inside micrometer onthe workbench.

4. Measure each brake drum and create a reference for yourself that lists themeasurements for each brake drum.

5. Change the installation of the brake shoes or brake hardware for each brakeassembly.

Components• Duo Servo & Leading-Trailing edge design brake drum assembly mock-up

• 2 brake drums


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Tools

Instructor: None

Technician:

• Brake drum micrometer set for diameter and out-of-round measurements(14” maximum diameter capacity)

• Inside micrometer set for taper measurements (with extensions that allowmeasurements up to 14”) for brake drum taper measurements

• J 29840 brake spring remover and installer

• J 8049 brake spring remover and installer

• J 8057 brake spring pliers

• J 21777-A brake drum/shoe clearance gauge



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Follow specifications, disassembly, and reassembly procedures outlined in SI:

Remove / inspect left rear and right rear brake shoes and related parts, including:

• Matchmark the brake drum to the wheel studs

• Remove the shoe return springs and hold-down springs

• Remove some of the park brake hardware

• Remove the shoe and lining assemblies

• Remove the remaining park brake hardware

• Inspect all parts for wear or damage

Correctly install left rear and right rear brake shoes and related parts, including:

• Identify the six brake shoe contact areas on the backing plate that require

lubrication• Identify the adjusting screw surfaces that require lubrication

• Install some of the park brake hardware

• Install the shoe and lining assemblies

• Install the remaining park brake hardware

• Install the shoe hold-down springs and return springs

• Perform the drum brake adjustment procedure steps

• Perform the park brake adjustment procedure steps

• Measure shoe to drum clearance

Measure braking surface of two brake drums:• Diameter

• Depth of grooves

• Out-of-round

• Taper

Determine status of braking surface for each brake drum:

• Is within specifications

• Can be refinished to be within specifications

• Must be replaced because refinishing will not bring it within specifications


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Workstation 5


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Morning Activities

Suggested Debrief Session - Page 1

Workstation #1:

What you did:

• Provided worksheets to outline diagnostic procedure for the Hall Effect /digital wheel speed sensor

What the students did:

• Answered questions about the diagnostic procedure and became familiarwith the operation and values of the Hall Effect / digital wheel speed sensor

Important job skills:

•

Learned to refer to Service Information for system variations in operationand diagnostic procedures

Workstation #2:

What you did:

• Re-Indexed SWPS 180 degrees


• Followed Service Information procedures to test the SWPS

• Read D&O to understand how the module uses analog and digital signals to

determine speed and direction of vehicle• Understood the importance of how the analog and digital signals work

together


• Learned to follow Service Information

• Used the TECH 2 and TIS to graph results


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Morning Activities


Workstation #3:

What you did:

• Created an open fault in the Wake up circuit, disabling the EBCM


• Followed Lean Diagnostics to diagnosis ‘No communication’ concern withthe EBCM


• Learned importance of reading D&O thoroughly

• Understood how to work through Lean Diagnostics• Gained knowledge of how Power Mode Master works and how it plays a

part with the wake up circuit

Workstation #4:

What you did:

• Machined rotor to create excessive lateral runout


• Followed procedures recommended by Technical Service Bulletins (TSBs)to identify and correct excessive brake rotor lateral runout

Important job skills:• Learned how to follow TSB information

• Used recently released special tools and repair parts


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Morning Activities


Workstation #5:

What you did:

• Provided mock-up of Duo-Servo and Leading/Trailing edge rear drumbraking assemblies

• Provided brake drums in various conditions


• Removed and inspected the rear drum brake parts and noted that someparts are incorrectly installed


• Learned how to follow Service Information for basic brake procedure

• Practiced measurements, disassembly and reassembly of rear brake drumcomponents. Noted the difference between the 2 systems.

• Referred to specifications and procedures located in Service Information

• Used tools to measure brake drums diameter, out-of-round, and taper


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Afternoon Activities

Overview

30 minutes before session beginsPreparation of Workstations:

• Set up Workstations 6, 7, 8, 9, and 10 (refer to set-up details on the pagesthat follow)

• Note that variations for each workstation may be available

5 minutes

Session Introduction:

• Workstations 6, 7, 8, 9, and 10

• Each student must demonstrate key skills at each workstation• Each workstation requires written documentation on work orders

150 minutes

Workstations:

• Student pairs rotate between workstations every 30 minutes

• Monitor work of student pairs (refer to expected technician path details onthe pages that follow)

• Use Required Student Skills form to record student achievement

30 minutes

Debrief Session:

• Highlights of Workstations 6, 7, 8, 9, and 10 (refer to the Debrief Session)


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Workstation 6



• Use strategy-based diagnostic principles to diagnose ABS concern



Station Set-Up

Vehicle: 2007 Chevrolet Malibu

Symptom: ABS light ON

Directions: Create on open circuit in the power feed at the EBCM to cause a ‘Nocommunication’ concern.


Fault Set-Up Steps:

1. Disconnect the EBCM connector, remove top cover and then the terminallock. Pull Ignition 1 voltage, cavity C, circuit 139 (Pink) from the connector.

2. Install a dummy terminal and pigtail in cavity C of EBCM connector, tapecircuit 139 into the harness to hide.

ComponentsNone


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Tools

Instructor:

• Small flat-blade screwdriver

• J 38125 terminal repair kit

• TECH 2

• Service Information

Technician:

• J 39200 DMM

• J 34142 Unpowered test light

• TECH 2

• Service Information

•

J38125 Terminal repair kit


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Perform Repair Procedures

Follow the Diagnostic Starting Point – Anti-lock Brake System InformationFollow the Diagnostic System Check – Vehicle Chart:

Step 1: Perform visual inspections.

Step 2: The scan tool powers up.

Step 3: The scan tool does not communicate with all the expected controlmodules.

Data Link References

Scan Tool Does Not Communicate with High Speed GMLAN Device

Step 1: Yes, performed Diagnostic System Check – Vehicle.Step 2: Scan tool communicates with other modules on GMLAN serial datacircuits.

Step 3: Yes, code is between U2105-2177 (U2108).

DTC U2105-2199

Step 1: Yes, performed Diagnostic System Check-Vehicle.

Step 2: Yes, Able to communicate with BCM.

Step 4: Not able to communicate with ALL modules.

Step 5: No Ignition 1 Voltage at EBCM.

Instructor Notes:

______________________________________________________

______________________________________________________

______________________________________________________

______________________________________________________

______________________________________________________


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Workstation 6


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Workstation 7



• Use strategy-based diagnostic principles to diagnose ABS concern

• Use TECH 2 to retrieve, view and clear codes


Station Set-Up

Vehicle: 2007 Saab 9-7x

Symptom: Customer states that the ABS light is ON.


Fault Set-Up Steps:

1. Gain access to the right front wheel speed sensor. Note that this involvesremoving the disc brake rotor.

2. Remove the wheel speed sensor and install a spacer ring on it that isfabricated by you (see photos on following page). Note that wrapping coathanger wire around a 7 mm 1/4” drive socket can create the spacer.

3. Install the wheel speed sensor with spacer ring, and then reinstall the partsremoved for access.

4. Operate the vehicle to confirm that the EBCM has stored DTC C0040 and hasturned on the ABS light.

Note: Ensure that students do not clear code before, during, or after exercise.

ComponentsSpacer fabricated by instructor (washers)


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Tools

Instructor: Hand tools

Technician:


• J 39200 digital multimeter




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Verify concern

Operate the vehicle and observe that the ABS light is ON


Follow the Diagnostic Starting Point – Anti-lock Brake System Information:

Proceed to the Diagnostic System Check – ABS chart

Follow the Diagnostic System Check – Vehicle

Step 1: Preliminary inspection OK

Step 2: The scan tool powers up

Step 3: The scan tool communicates with expected vehicle control module

Step 4: Power mode matches switch positions

Step 5: The engine cranks

Step 6: The scan tool does not display either of the DTCs listed; engine idles

Step 7: Scan tool displays C0040

Step 8: The scan tool does not display U-codes

Step 9: The scan tool does not display listed codes

Step 10: Vehicle trouble code list - Vehicle

Follow the C0035 or C0040 chart:

Step 1: The ABS Diagnostic System Check - Vehicle was performed

Step 2: DTC C0040 sets at a vehicle speed of 12 mph

Step 3: The right front wheel speed sensor resistance is between 700 - 10,000ohms

Step 4: The right front wheel speed sensor AC voltage is less than 100 mV

Step 8: Recommend replacement of the right front wheel speed sensor

Instructor Notes:

______________________________________________________

______________________________________________________

______________________________________________________


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Workstation 7


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Workstation 8



• Use strategy-based diagnostic principles to diagnose traction controlconcern


• Use TECH 2 to view data list and be able to interpret data


• Diagnose using symptoms only

Station Set-Up

Vehicle: 2007 Buick Lucerne w/JL4 or Cadillac DTS w/JL4

Symptom: Customer states that the Traction Control light is ON and the ‘ServiceStability’ message is displaying in the DIC.


Fault Set-Up Steps:

1. Remove Trans Control module and bracket.

2. Gain access to inline C111 on the driver side strut tower.3. Pull low reference circuit 719 PU from terminal A2.

4. Install dummy circuit in terminal A2.

5. Remove rear driver seat bolts in order sensor cluster access can be gained.

ComponentsNone; wire fault


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Tools

Instructor: Hand tools

Technician:


• J 39200 digital multimeter




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Verify concern

Operate the vehicle and observe that the Traction Control light on with ServiceStabilitrac message appears in DIC

Tech is able to check the sensor cluster voltage at the cluster under the driversseat.


• Diagnostic System Check – Vehicle

• DTC list - Vehicle

Circuit/System Testing

C0196 28

1. Ignition OFF, disconnect the yaw rate sensor/lateral accelerometer connectorand EBCM connector.

2. Test for infinite resistance between the yaw rate frequency circuit and ground.

⇒ If less than infinite resistance, test the yaw rate frequency circuit for a short

to ground.

3. Test for less than 1 ohm of resistance on the yaw rate frequency circuit

between the yaw rate sensor/lateral accelerometer connector and EBCMconnector.

⇒ If greater than 1 ohm, test the yaw rate frequency circuit for an open/high

resistance.

4. Replace yaw rate sensor/lateral accelerometer, and clear the yaw rate sensoroffset value in the EBCM. If C0196 28 is still current, replace the EBCM.

SI can not address every issue that may arise associated with a DTC orsymptom. When working with the new Lean Diagnostics it is assumed thatthe DSC-V is being followed. In the DSC-V many things need to be donethouroughly, such as inspect fuses and connections. When the circuit

testing is performed it is crucial that you ensure that all powers, grounds,and communications are adequate at the component(s) even though SI maynot specifically indicate that particular test. Always check the basics beforepart replacement even if the test is not spelled out. Use all resources suchas schematics, D&O, and the scan tool data parameters and specialfunctions in order to make a well educated repair.


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Advise the tech that the EBCM and sensor cluster have been replaced and theconcern still exists. The technician needs to check all circuits at the module and orfollow steps for the 00 symptom code.

C0196 00

1. Ignition OFF, disconnect the yaw rate sensor/lateral accelerometer connector.

2. Ignition OFF, test for less than 1 ohm of resistance between the low referencecircuit and ground.

⇒ If greater than 1 ohm, test the low reference circuit and the EBCM ground

circuit for a short to voltage or an open/high resistance. If the circuits testnormal, replace the EBCM.

3. Test the lateral accelerometer signal circuit, the 5-volt reference circuit, and thelow reference circuit for an open/high resistance or a short to voltage orground.

⇒ If all circuits test normal, replace the yaw rate sensor/lateral accelerometer,

and clear the yaw rate sensor offset value in the EBCM.

⇒ If the DTC sets again after replacing the yaw rate sensor/lateral

accelerometer, replace the EBCM.

The technician then takes measurements at the sensor cluster. The technician willnote that voltage is present on the low reference circuit (there is approximately 3

volts when no voltage should be present under correct conditions). This willindicate that an open fault exists on circuit 719. Two of the original 5 volts is beingbled through the sensor into other areas of the sensor cluster leaving 3 volts onthe low reference circuit.


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Workstation 8


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Workstation 9

Objective

After completing this workstation exercise, each student will be able to:

• Properly use brake line flaring tool

• Make a double-flare and an ISO flare

• Perform preparation, bending, and cutting procedures

Station Set-Up

Vehicle: None (workbench activity)


Fault Set-up Time: Less than 5 minutes with workbench area preparationcompleted prior to course.

Fault Set-Up Steps:

1. Fabricate a sample brake pipe that involves making bends, making a double-flare fitting end, and making an ISO-flare fitting end.

2. Provide lengths of brake pipe that are longer than required for fabricationaccording to the sample.

3. Provide double-flare and ISO-flare fitting nuts for each line to be fabricated.

4. Provide tools for brake pipe cutting, bending, and flaring.

ComponentsLengths of brake pipe, double-flare fitting nuts, and ISO-flare fitting nuts

Tools

Instructor:

• Brake pipe cutting tool

• Brake pipe bending tool

• J 45405 flaring kit

Technician: • Brake pipe cutting tool

• Brake pipe bending tool

• J 45405 flaring kit


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Perform Repair Procedures

Fabricate a replacement brake pipe that matches the sample provided:• Install an appropriate flare fitting nut and make the required type of flare

fitting on one end of the steel tube

• Bend the steel tube

• Cut the steel tube at the other end, taking into account the additional lengthneeded for the required type of flare fitting end

• Install the appropriate flare fitting nut and make the required type of flarefitting on the steel tube

Instructor Notes:

______________________________________________________

______________________________________________________

______________________________________________________

______________________________________________________

______________________________________________________


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Workstation 10



• Identify variety of surface conditions on rotors and drums

• Properly use measurement tools for drums and rotors

• Properly use brake lathe and refinishing procedures

Station Set-Up

Vehicle: Workbench activity


Fault Set-up Time: Less than 5 minutes with workbench preparation completedprior to course.

Fault Set-Up Steps:

1. Obtain 4 rotors from a variety of vehicles, with an assortment of surfaceconditions (grooves, excessive out-of-round, and excessive taper).

2. Attach identification tags to each brake drum / rotor for student reference tospecifications in Service Information for related vehicle.

3. Place the rotors and an outside micrometer set on a workbench.4. Measure each rotor; create a reference for yourself that lists the

measurements for each brake drum.

5. Prepare the brake lathe for use in refinishing rotors, including necessarymounting adapters, sharp cutting bits and a non-directional finishing tool (or asanding block with 120 grit aluminum oxide sandpaper).

6. Print Doc ID# 1510324 and highlight brake lathe calibration procedure.


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ComponentsFour brake rotors

Tools

Instructor: None

Technician:


• Brake lathe, with user's manual, accessories, replacement cutting bits and anon-directional finishing tool

• Disc brake micrometer set


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Refinish two disc brake rotors (one per student):• Measure the rotor thickness to determine if it can be refinished (refer to

Brake Rotor Thickness Measurement in Service Information forspecifications)

• Measure thickness variation

• Use the brake lathe manufacturer's information to qualify the trueness of thelathe arbor

• Use the brake lathe cutting bits to refinish the rotor according to the BrakeRotor Refinishing procedures located in Service Information

• Use a non-directional finishing tool (or a sanding block with 120 gritaluminum oxide sandpaper) to apply a non-directional finish

Instructor Notes:

______________________________________________________

______________________________________________________

______________________________________________________

______________________________________________________


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Workstation 10


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Workstation #6:

What you did:

• Created an open fault in the EBCM ground circuit


• Followed Service Information procedures to isolate an open circuit in wiringthat resulted in no EBCM functions, including communication with a scantool


• Followed Service Information for specific ABS diagnostics

• Used the TECH 2 scan tool functions related to ABS diagnosis

• Briefed overview of GMLAN

• Consulted schematic as needed for logical isolation of concern

Workstation #7:

What you did:

• Shimmed the right front wheel speed sensor to create an excessive air gap

What the students did:• Followed Service Information procedures to isolate a wheel speed sensor

that is producing an inadequate AC voltage


• Followed Service Information for ABS diagnostic procedures

• Used the TECH 2 scan tool functions related to ABS diagnosis

• Understand how the variable reluctant sensor functions and how to test it


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Workstation #8:

What you did:

• Installed a BCM with an internal fault related to the traction control switch


• Followed Service Information procedures to isolate an internal fault in theBCM that resulted in no change in status of the traction control switch inputto the EBCM


• Followed Service Information for TCS diagnosis

Alternate Workstation #8:

What you did:

• Pulled low reference circuit from the sensor cluster to simulate open circuit


• Followed Service Information procedures to examine wiring schematics,and checked voltages using the DMM


• Using lean diagnostics and understanding that SI can not address everyscenario and utilizing wiring schematics

• Understanding the importance of reading D&O, understanding what type ofvoltage or resistance readings should be present on a component

• Performing all component testing even if not specified in SI, beforecondemning a module

•

Workstation #9:

What you did:

• Fabricated a sample brake pipeWhat the students did:

• Fabricated a replacement brake pipe that matches the sample


• Used tools to make brake pipe flares

• Used tools to bend and cut lengths of brake pipe


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Workstation #10

What you did:

• Provided rotors in various conditions


• Measured each brake rotor and determined its status for resurfacing:

Rotor #1: _______________________________________

Rotor #2: _______________________________________

Rotor #3: _______________________________________

Rotor #4: _______________________________________

• Qualified the brake lathe arbor for trueness

• Resurfaced two rotors and applied a non-directional finish


• Used tools to measure brake rotor thickness

• Used tools to resurface and apply a non-directional finish to brake rotors

Documents

15045.11 GM Braking Systems