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2004 LSSV Service Manual Supplement

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1. 0 5 2004 Light Service Support Vehicle LSSV 5 0 5 5 2 coire 0 6 2004 LSSV Truck 0 2 Table of Contents General Information BLANK 2004 LSSV Truck General Information General Information Vehicle Identification The 2004 LSSV series military pickup and utility models derive from standard commercial vehicles The pickup is a 2500HD or 1 ton based cargo troop carrier The utility is a 1500 series Tahoe based military command vehicle All vehicles have rugged designs intended for all types of roads or infrequent off road travel They can ford water obstacles for three minutes without stalling at depths of 51 cm 20 in at 8 kph 5 mph These limits are met without causing permanent damage or requiring immediate maintenance Each vehicle is equipped with heavy duty shocks front and rear 4 wheel anti lock brakes a locking differential on off road tires front and rear clevis tie downs and blackout B O lighting A slave receptacle is mounted on the front of the vehicles protected by a radiator brush guard Pickup Vehicle Information The pickup vehicle is equipped with a 6 6L Turbo diesel engine with a 5 speed Allison automatic transmission and 2 speed transfer case Payload capacity is not to exceed the gross axle weight rating of the front and rear axle The pickup has a cargo co
2. 6 20 Stoplamps Diagnosis Blackout Stoplamps Inoperative 8 90 T Taillamp Repair Taillamp Replacement Maintenance BOGOV c Estates tpi iem e OS 8 107 Taillamp Bulb Repair Taillamp Bulb Replacement Maintenance spo RE 8 108 Tie Down Plate Repair Tie Down Plate Replacement Rear Maintenance 8 152 Tire Tire Hoist Shaft Extension Replacement 3 3 Tires and Wheels Description Spare Wheel Hoist Shaft 3 4 Repair Tire Hoist Shaft Extension Replacement 3 3 Topper Dome Lamp Repair Topper Dome Lamp Bulb Replacement 8 103 Topper Dome Lamp Switch Replacement Mies 8 113 Topper Dome Lamp Switch Replacement acr 8 112 Trailer Hitch Reinforcement Plate Replacement Maintenance Body 8 181 Description Transfer Case Vent Tube Filter 4 8 Repair Transfer Case Vent Tube Filter Replacement eese 4 7 Turn Signals Turn Signals Operate in Blackout B O Mode 8 96 Vehicle 0 3 Vehicle Load Repair Vehicle Load Disconnect Switch Replacement eese 6 38 Voltmeter Repair Voltmeter 8 119
3. A 10561 Connector Part e 12015791 Information e 1 Way Weather Pack BLK Pin Wire Circuit Function Color No A BRN WHT 900 Blackout B O Marker Lamps Supply Voltage 2004 LSSV Truck ody and Accessories Blackout B O Service Switch Lighting Systems 8 85 Blackout B O Lamps Right Rear 1 G E E zs B 10563 10574 Connector Part 08917695 Connector Part e 12010973 Information e 6 Way Series 58 Information 2 Way M Weather BLK Pack BLK Pin Wire Circuit Function Pin Wire Circuit Function Color No Color No A PNK 911 Blackout B O Drive A GRN 902 Blackout B O Lamp Switch Signal WHT Stoplamp Supply B ORN 40 Relay Block I P 21808 Voltage B BRN 900 Blackout B O C ORN 912 Blackout B O SET Marker Lamp Supply Voltage Control Signal __ Blackout B O L Left R amps Le ear D WHT 913 Fuse Block Left I P ackout B O Lamps Voltage E WHT 17 Stoplamp Switch Signal F DK GRN 902 Blackout B O WHT Stoplamps Signal 10574 Connector Part e 12010973 Information e 2 Way M Weather Pack BLK Pin Wire Circuit Function Color No A GRN 902 Blackout WHT Stoplamp Supply Voltage B BRN 900 Blackout WHT Marker Lamp Supply Voltage 2004 LSSV Truck 8 86 Lighting Systems Body and Accessories D
4. JOJJ9AUO2 9 9jelS PHOS 13141099H J MOd AvC J0 e13U99 aja v 291 8 d os esnj __ _ n YOZ L SI9Iend Jexyeoaug 92 AHO uonounr 8 0 8 SC N38 80 jeubis 5 a i King 1ojeoipu i 033002 pl 4 eBieyo i 2004 LSSV Truck Engine 6 8 Engine Electrical swajshs Ul asni poousapun sAejay Ave B E S pilos Jaynooy YSZ esnj Joes Ave Y soneueuos 6008 18 03 8 0 AZ 5 wa 0 5 6008 80 18 038 0 A18 Q038 0 8008 N38 80 6008 9 0 6L Ts 1 Pes seS eee gt 1 1 YANI _ v Q dnxoid Apc 2004 LSSV Truck Engine Electrical 6 9 Engine 05 19 80 05 41d 80 OS 19 80 Wr0co4 6841 ANd c Jejeun oA Ave V 6 NH880 WrOcd Ww OSL 1d 2 624 ANd Z 98 Ave 98 L06 NHO C VOL 3 esnj Joxyeeug nop Ave 0 1d 8 5 _ E
5. 8 161 Frame and Underbody Description Frame and Underbody Description 8 183 Repair Military Rear Receiver Hitch Replacement Utility tt t DERE REI 8 181 Trailer Hitch Reinforcement Plate Replacement Maintenance Body 8 181 Specifications Fastener Tightening Specifications 8 179 Front Drive Axle Description Front Axle Vent Tube Filter 4 4 Repair Front Axle Vent Tube Filter Replacement 4 3 Function Tables sese eee 8 115 G Generator Repair 24V Generator Replacement 6 36 Government Vehicle Data Plate Replacement 8 160 Grille Repair Grille Refinishing sse eee eee eee eee ee e 8 178 Repair Gun Rack Replacement Floor Mount Utility 54 aa a 8 163 Gun Rack Replacement Floor Mount Crew Cab itti emn 8 162 Gun Rack Replacement Upper 8 164 Gun Rack Support Replacement Lower 8 164 H Headlamp Repair Headlamp Replacement Blackout B O PICKUP UN 8 99 Repair Headlamp Bulb Replacement Blackout pee E EE 8 100 Headlamp Replacement Blackout B O QUITAR EE 8 99 Hi Beam Headlamps Diagnosis Index Hi Beam Headlamps Operate in Blackout 8 97 Description Horn with Blackout B O Control Circuit Operation
6. 3 Trailer Harness Connector Military License Plate Lamp 4 Maker Lamp Harness Connections 5 Blackout B O Marker Lamps 2004 LSSV Truck Body and Accessories Lighting Systems 8 81 Trailer Wiring Harness Utility Legend 1 Bumper 4 Trailer Connector 2 C900 5 Trailer Connector Cover 3 C901 2004 LSSV Truck 8 82 Lighting Systems Body and Accessories Relay Block Legend 1 Turn Signal Relay 5 Headlamp Low Beam Relay 2 Park Lamp Relay 6 DRL Relay 3 Headlamp Hi Beam Relay 7 Horn Relay 4 Interrupt Wiring Harness 2004 LSSV Truck Body and Accessories Lighting Systems 8 83 Lighting Systems Connector End Views License Plate Lamp Blackout B O Headlamp 10565 Connector Part e 12010996 7927 Information e 1 Way M Weather Connector Part e 12110053 Pack BLK information e Lamp Socket Type Pin Wire Circuit Function W 2 Axial LT GRY Color No Pin Wire Circuit Function A TAN WHT 901 Blackout B O Color No Headlamp Supply A BLK 19 Ground Voltage B BRN 915 Lamp Supply Voltage Blackout B O Drive Relay Blackout B O Drive Lamp Switch E E p 3 AVR pn Relay Control Voltage 85 10550 Connector Part 12129716 informan e 4 Way F MIP Series 280 GRY Pin Wire Circuit Function Color No 86 WHT 915 Blackout B O Drive
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8. 8 176 Body Rear 8 176 Paint Coatings 8 177 Paint Codes eese 8 177 Repair Instructions eese 8 178 Exterior Painting 8 178 Grille 8 178 Frame and Underbody 8 179 Specifications eere 8 179 Repair Instructions eese 8 181 Military Rear Receiver Hitch Replacement d Fete o Receta 8 181 Trailer Hitch Reinforcement Plate Replacement Maintenance 8 181 Description and Operation 8 183 Frame and Underbody Description 8 183 Body and Accessories Wiring Systems 8 3 Wiring Systems Specifications Fastener Tightening Specifications Specification Application Metric English Fender Brace Bolts 25 Nem 18 Ib ft Front Winch Ground Cable Bolt 34 Nem 25 Ib ft Junction Block Nut 9 N m 80 Ib in Trailer Connector Bolts 5 Nem 44 Ib in Winch Connector Bolt 5 8 N m 44 71 16 in Winch Harness Clamp Bolt 18 29 Nem 13 21 Ib ft Schematic and Routing Diagrams 2004 LSSV Truck Body and Accessories 8 4 Wiring Systems YOUMS joeuuoosiq AC 1 peo _ I k esn4 __
9. information Lighting Systems sese eee eee eee 8 61 General 1 0 3 Instrument Panel Gages and Console 8 117 Maintenance and Lubrication 0 9 TOMS IP EE 8 123 Extorior TAM iiie ii iiit rk ERR 8 129 Suspension BumpelrS nci ere ett ec aig 8 133 Tires and Wheels 3 3 c MEM uH MR 8 155 vali Interior Tm 8 159 Driveline Axle Body ROB Enid a o 8 167 Front Drive Axle 4 3 e 8 177 Rear Drive Axle sees 4 5 Frame and Underbogy e 8 179 Transfer Case 4 7 INDEX Denon tts INDEX 1 Engine Engine Electrical eee 6 3 2004 LSSV Truck 2 Table of Contents Table of Contents BLANK 2004 LSSV Truck General Information Table of Contents 0 1 Section 0 General Information General Information 0 3 Maintenance and Lubrication 0 9 Vehicle Identification 0 3 Maintenance eere 0 9 Pickup Vehicle Information 0 3 Owner Checks and 0 9 Utility Vehicle Information 0 4 Periodic Maintenance Inspection 0 9 Military Equipment Options
10. Specifications Fastener Tightening Specifications Specification Application Metric English Seat Bolts 88 Nem 65 Ib ft 2004 LSSV Truck 8 156 Seats Body and Accessories BLANK 2004 LSSV Truck Body and Accessories Seats 8 157 Repair Instructions Seat Replacement Troop Removal Procedure Notice Note the clamp and stud arrangement for installation later 1 Remove the 2 bolts nuts and clamps holding the seat assembly to the box rail 2 Fold the seat section to the seatback and install the tether pins to the locking holes for easy removal 3 Remove the 2 bolts and nylock nuts from the end of the rail 4 Remove the troop seat assembly Installation Procedure Notice The left and right seat assemblies are not interchangeable Match the mounting hole pattern of the seat assembly before attempting to install 1 Unfold the third seat back from the cab down Notice Refer to Fastener Notice in Cautions and Notices 2 When properly aligned install the 2 bolts screws and nuts to the end of the rail Tighten Tighten the bolts to 88 N m 65 Ib ft 3 Install the 2 clamps bolts and nuts holding the seat assembly to the holes within the openings at the middle and forward end of the box rail Tighten Tighten the bolts to 88 N m 65 Ib ft 2004 LSSV Truck 8 158 Seats Body and Accessories Description and Operation Folding Rear Seat The troop seats provide 2 benches with
11. dnyold uonnqujsiq G Has A plous og SONEWSYIS S Jeueis dnyold AZL 2 uiejs g uonounf v008 Q34 80 006 8 0 dnydig M peg 2004 LSSV Truck Engine Electrical 6 5 Engine 5 ul Anil APZ ACL uonnquisiq Jewog suiejs S BuutM ut Aul APZ ACL uonnqujsiq Jewogd Soneuleu s AZ L W3 S S xoolg uonounrf ___ ____ 61 G Jeuejs S 1 O 1d ZE 2004 LSSV Truck Engine 6 6 Engine Electrical L 029 0 AZL 14604 ieyeg LL L a3 8 i oolg 9514 1 006 L L uaus 210 peo JOHEIS 9jotuoA 1 a c 6L 4 yoolg uonounf pooujepufi c N23 e npoy Jou02 1 dnydid soneuieuos eyes pilos 91215 e qisn4 8 SC 80 Sc N38 80 JeuBig ejo MnO soyeorpuy JojeJeuac 2004 LSSV Truck Engine Electrical 6 7 Engine uoyounr Jeuels G Jouejs L ce
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13. 006 Q33 L poousepun 72018 uonounf dnyoid AZL uonnguisiq uonnquisigq 19MOg 2004 LSSV Truck Systems 8 5 Wirin Body and Accessories dn yoig 9019 asni dnxyoig oneuieuog Aueyeg 8008 9 80 VOL asn4 Ave 6008 6008 80 1 Ave 9 9 Raet voos 8 9006 18 03 Z 80 jur POLS Joyesaueg 8 NUIT 6008 18 033 eiqisn4ll 8 oz 1 6008 STE 18 03 08 6008 18 03 08 YMS yOSULONSIG peo dnyoid Ave uonnquisiq 2004 LSSV Truck Body and Accessories Systems 8 6 Wirin uonounf YOUIM _ 5 _ Q38 6 een Gay 8 Hd yoolg a uonounf Gay ce ce JBUSAUOD asn4 291 8 006 02919 8 LI Su 6 L VOS 006 034 L Joyeoig Ave 006 8 AMIN AbZ AZL uonnquisig 2004 LSSV Truck Wiring Systems 8 7 Body and Accessories Aejay 1dnueju L 2 6 NHO 0 UOM soles uonnquisig L Ov NYO 2004 LSSV Truck Body and Accessories 8 8 Wiring Systems 80 OSL 41d 01
14. 1 Install the upper gun rack assembly 2 by aligning to the body side inner upper panel Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts 1 to the assembly Tighten Tighten the bolts to 8 Nem 70 lb in 3 Install the lower rear window molding Refer to Molding Replacement Rear Window Lower in Interior Trim in the 2004 C K Truck Service Manual 2004 LSSV Truck 8 166 Interior Trim Body and Accessories Description and Operation Interior Description The interior trim options for these military vehicles include special gun racks for the M14 and M16 firearms Refer to the 2004 LSSV Owner s Manual Supplement for gun rack operation and use 2004 LSSV Truck Body and Accessories Body Rear End 8 167 Body Rear End Specifications Fastener Tightening Specifications Specification Application Metric English Cargo Cover Bow Strap Retaining Nuts 5 Nem 44 Ib in Cargo Cover Front End Rail Bolts 8 70 Ib in Cargo Cover Rail and Hinge Upward Bolts 8 70 Ib in Cargo Cover Rail Outside Bolts 26 Nem 19 Ib ft Cargo Cover Strut Bolts 5 Nem 44 Ib in Fiberglass Top Bolts 68 Nem 50 Ib ft Maintenance Body Bolts 85 Nem 63 Ib ft 2004 LSSV Truck 8 168 Body Rear End 2004 LSSV Truck Body and Accessories Repair Instructions Fiberglass Top Replacement Removal Procedure 1 Remove the electrical connection for the light 2 Remo
15. LHM NUS 80 206 LHM NYS 8 0 LHM 0 L LHM 206 80 ynoyoe gq jd 31 duie duie Joey ynoyoe q ynoyoe q 9jeld 2 006 0 L 0 L 006 LHM LOG NV L 80 Bunubr 2004 LSSV Truck Lighting Systems 8 67 Body and Accessories dwe V 8 BunuBr 2004 LSSV Truck Body and Accessories 8 68 Lighting Systems 09 19 189 80 80 Joes Hepy 0060 YO7 YVWOLGOYO ya YVWL0O6OD BL NO 80 S8 3 joyelg 0 AvC 98 LHM 006 NYd 9 0 N dnyoid 191611 c08 10299 02 W6069 Y V 0 N9 8 0 18 d3 02 S8 Aejay ynoyoe g 01 AvC 98 LHM 06 NHO 0 A 2004 LSSV Truck Systems 8 69 Lightin 2004 LSSV Truck Body and Accessories Jojre1 L 7007 0 19J9M 006 N48 90 due esue9r LHM 06 L 49011211 Body and Accessories Systems 8 70 Lightin enuen yond M O v00c 01 19J94 esn4 4 pejoeuuoosiq BuuiM Bunsix3 269 NN9 L1 8 0 jenueyy 941
16. 85 TAN WHT 901 Blackout B O Headlamp Supply Voltage 87 PNK 911 Blackout B O Controls Signal 30 BRN WHT 901 Blackout B O Headlamp Switch Signal B 10566 Connector Part e 08911352 Information e 5 Way F Series 56 BLK Pin Wire Circuit Function Color No E ___ Not Used B TAN 901 Blackout B O WHT Headlamp Supply Voltage C PNK 911 Blackout B O Drive Lamp Switch Supply Voltage D WHT 915 Blackout B O Control Relay Signal E BLK 150 Ground 2004 LSSV Truck 8 84 Lighting Systems Blackout B O Lamps Fuse Body and Accessorie Trailer Lamp Connector S J HH B A 10567 Connector Part e 12010105 Information 2 Way M Weather Pack BLK Pin Wire Circuit Function Color No A J A BRN WHT 900 Blackout B O Marker Lamps Signal B PNK 911 Blackout B O Controls Supply Voltage Blackout B O Marker Lamp Front pM 10562 Connector Part 08917884 Information e 12 Way Weather Pack BLK Pin Wire Circuit Function Color No A BRN 900 Blackout B O Marker Lamps B YEL 18 Brake Taillamp Supply Voltage BRN 900 Blackout Control Circuits BLK 150 Service Stoplamps E BRN 9 Stoplamp Switch Output F DK GRN 902 Blackout Brakelamps H BRN 900 Blackout Brakelamp J DK GRN 19 Brake Taillamp Supply Voltage K N E Not Used
17. Did you correct the condition System OK Go to Step 2 2004 LSSV Truck 8 88 Lighting Systems Body and Accessories Blackout B O Headlamp Always On Step Action Yes No Schematic Reference Lighting Systems Schematics 1 Did you review Blackout B O Lighting Description and Go Description and Operation Go to Step 2 Operation Place blackout B O drive lamp switch in OFF mode Connect a test lamp between blackout B O drive lamp 2 switch cavity B circuit 901 TAN WHT to ground Does the test lamp illuminate Go to Step 3 Go to Step 4 Replace blackout B O drive lamp switch Refer to Blackout B O Switch Replacement in Instrument Panel Gages and 3 Console gt Did you complete the replacement Go to Step 5 Repair short to power in circuit 901 TAN WHT or inoperable 4 blackout B O control relay Did you find and correct the condition Go to Step 5 E Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 Headlamps Operate in Blackout B O Mode Step Action Yes No Schematic Reference Lighting Systems Schematics 1 Did you review Blackout B O Lighting Description and Go to Description Operation Go to Step 2 and Operation 1 Place blackout B O service switch into the blackout B O mode 2 2 Connect a test lamp from cavity 85 at the blackout B O lighting drive relay and ground Does the test lamp ill
18. Power and Grounding Component Views Inline Harness Connector End Views C101M 1 Cavity Front right of the front bumper for right front blackout B O marker Power and Grounding Component Views Inline Harness Connector End Views C102M 1 Cavity Front left center of grille for blackout B O headlamp Power and Grounding Component Views Inline Harness Connector End Views C103M 2 Cavities C105M 4 Cavities Left side of engine compartment for front lighting harness Engine compartment by Underhood fuse block Inline Harness Connector End Views Inline Harness Connector End Views C106M 3 Cavities Engine compartment by Underhood fuse block Inline Harness Connector End Views 2004 LSSV Truck 8 14 Wiring Systems Body and Accessories Master Electrical Component List cont d Name Location Locator View Connector End View C107M 1 Cavity Engine compartment by Underhood fuse block Inline Harness Connector End Views C108M 2 Cavities C301M 2 Cavities Left rear frame rail towards rear of the vehicle Under I P for topper lamp Inline Harness Connector End Views Inline Harness Connector End Views C302M 2 Cavities Under UP for brake lamps Inline Harness Connector End Views C303M 1 Cavity Relay block I P C4 Cavity E Inline Harness Connector End Views C304M 2 Cavities Blackout B O
19. Relay Block C5 rat mop ee 1560 u Connector Part 12193930 Information 2 e 6 Way Metri Pack 280 Connector Part 12193928 Series Flexlock BLK Information 6 Way Metri Pack 280 Series Flexlock GRY Pin Wire Circuit Function Color No Pin a 2340 Battery Positive Voltage 5G4 TRW B 72 Not Used PPL WHT 1382 LED Dimming Signal ORN 40 Blackout Service ZX3 Switch PPL WHT 1382 LED Dimming Signal D Not Used 5G4 5X7 5Y0 TRW E ORN 4540 Battery Positive Voltage C TAN WHT 1384 Selective Ride Control 5G4 5X7 5Y0 TRW itch Si ZX3 BLK 1050 Ground TRW PNK 739 Ignition 1 Voltage ZX3 BLK 150 Ground BRN 9 24V Meter Supply Voltage 2004 LSSV Truck Body and Accessories Wiring Systems 8 29 Inline Harness Connector End Views Inline Harnes s Connector C100M A 10561 10565 e 12015791 e 12010996 Connector Part Connector Part e 1 Way F Weather Pack 1 Way M Weather Pack Information BLK Information BLK 1 Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function A BRN WHT 900 Blackout B O A BLK S Blackout B O Marker Lamp RF Marker Lamp RF Supply Voltage Supply Voltage Inline Harn
20. 12 13 Locate and repair open in circuit 911 PNK between blackout B O service lamp switch and blackout B O drive relay Did you complete the repair Replace blackout B O drive relay Did you complete the replacement Go to Step 20 Go to Step 20 14 Connect a test lamp from the blackout B O service switch at cavity B circuit 40 ORN and ground Does the test lamp illuminate Go to Step 19 Go to Step 18 15 1 Disconnect blackout B O headlamp switch 2 Connect a self powered test lamp between blackout B O headlamp switch cavity E circuit 150 BLK and ground Does the test lamp illuminate Go to Step 16 Go to Step 17 16 Replace blackout B O headlamp switch Refer to Blackout B O Switch Replacement in Instrument Panel Gages and Console Did you complete the replacement Go to Step 20 17 Locate and repair open in circuit 150 BLK wire between blackout B O headlamp switch and ground Did you complete the repair Go to Step 20 18 Locate and repair open in circuit 40 ORN wire between connector C241 and blackout B O service lamp switch cavity B Did you complete the repair Go to Step 20 19 Replace blackout B O service switch Refer to Blackout B O Switch Replacement in Instrument Panel Gages and Console Did you complete the replacement Go to Step 20 20 Operate the system in order to verify the repair
21. BLK 1750 Ground BLK 150 Ground D DK GRN 1619 Right Stop Turn D DK GRN 19 Right Stop Turn Supply Voltage Supply Voltage 2004 LSSV Truck 3 8 44 Wiring Systems Body and Accessories BLANK 2004 LSSV Truck Body and Accessories Wiring Systems 8 45 Repair Instructions Auxiliary Lamp Harness Replacement Front Removal Procedure 1 Remove the radiator grille 2 Remove the filler panel 3 Trace the auxiliary harness connections to the original harness Caution Refer to Battery Disconnect Caution in Cautions and Notices 4 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 5 Remove the connector from the right hand 6 and left hand 5 blackout B O marker lamp 6 Remove the nut to the ground lead and all wiring harness straps connecting the auxiliary harness 7 Remove connector 4 and ground from blackout B O headlamp mounting stud 8 Trace the auxiliary harness under the washer fluid reservoir and remove the wiring harness straps along the fender interior 9 Trace the auxiliary harness under the battery tray area and remove the wrap 10 Remove the forward auxiliary harness 2 from the vehicle 11 Remove the wiring harness straps near the bulkhead and disconnect the forward connector of the auxiliary harness from the auxiliary I P harness connector Installation Procedure 1 Connect the forward connector of the auxiliary harn
22. Blackout B O Lighting Description This section focuses on the function and service of the blackout B O headlamp the front and rear blackout B O marker lamps and the service blackout B O lamp switch All other lamps are covered in the 2004 C K Truck Owner Manual As military options the blackout B O lamps provide a stealthy low illumination alternative to standard lighting systems also available on these vehicles The blackout B O headlamp is identical on these vehicles The front blackout B O marker lamps are mounted in the bumper of the pickup vehicle and on the brush guard of the utility vehicles The rear blackout B O marker lamps are arranged in the same relative positions on each of the rear bumpers The service blackout B O lamp switches mounted at the lower center dash control blackout B O lamp and standard lamp functions A pair of toggles operates these switches The blackout B O drive toggle is mounted on the right When the service light toggle is moved up to the ON position it activates all service lights and enables all normal service light functions elsewhere to be turned ON if needed When moved to the ALL OFF position this toggle shuts off all lamps and auxiliary lamps When the switch is moved to blackout B O ON only the blackout B O lighting will work which includes the blackout B O markers front and rear and the blackout B O headlamp Within the rear marker lamps are separate color ma
23. Connector Location 6 7 8 2 C8 Connector Location Cavity D Map Receptacle If equipped Cavity F 24V Meter Relay Block I P p lt gt gt DHS Da 2 3 C5 Connector Location 4 Cavity E 24V Meter Ground 2004 LSSV Truck 8 24 Wiring Systems Body and Accessories Slave Receptacle Assembly Pickup Legend 1 Battery Negative Ground Black 3 Slave Receptacle Cover 2 Battery Positive Power Red 4 Slave Receptacle 2004 LSSV Truck Body and Accessories Wiring Systems 8 25 Slave Receptacle Assembly Utility Legend 1 Battery Positive Power Red 3 Slave Receptacle Cover 2 Slave Receptacle 4 Battery Negative Ground Black 2004 LSSV Truck 8 26 Wiring Systems Body and Accessories Front Winch Harness Routing Legend 1 Harness Clamp 3 Positive Winch Cable to Junction Block 2 Front Winch Prep Connector 4 Negative Winch Cable to Engine Block 2004 LSSV Truck Body and Accessories Wiring Systems 8 27 Winch Prep Harness Routing Rear 1 I dU nn Q7 BEY ANN A S QN IA 2 8 SS 6 7 foy SS Legend 1 Winch Connector 4 Harness Clamp 2 Multi Mount Winch Not included in Prep 5 Wiring Harness Straps 8 Harness to Junction Block 2004 LSSV Truck 8 28 Wiring Systems Body and Accessories Electrical Center Identification Views Relay Block I P C8
24. Installation Procedure 1 Install the clevis tie downs onto the bumper Refer to Clevis Tie Down Replacement Front 2 Support the bumper assembly by using an approved support system 3 Using the aid of an assistant position the bumper assembly onto the vehicle 2004 LSSV Truck Body and Accessories 8 136 Bumpers Notice Refer to Fastener Notice in Cautions and Notices 4 Install the 2 bolts and 2 nuts onto the center bumper supports Tighten Tighten the center bumper support bolts to 122 Nem 90 Ib ft 5 Install the 4 bolts onto the lower bumper supports Tighten Tighten the lower bumper support bolts to 77 Nem 57 Ib ft 6 Install the 2 bolts onto the upper bumper supports Tighten Tighten the upper bumper support bolts to 31 Nem 23 Ib ft 2004 LSSV Truck Body and Accessories Bumpers 8 137 7 Install the 3 bolts and the 3 clamps onto the blackout B O harness the slave receptacle and the bumper assembly 8 Install the blackout marker lamps onto the bumper Refer to Marker Lamp Replacement Front Blackout B O Pickup in Lighting Systems 9 Install the slave receptacle onto the bumper Refer to Slave Receptacle Replacement 10 Install the blackout B O headlamp onto the bumper Refer to Headlamp Replacement Blackout B O Pickup in Lighting Systems 11 Install the front winch connector Refer to Winch Connector Harness Replacement Front in Wiring Systems
25. Push up the battery tray 2 and remove from frame Caution Do not let the battery posts touch the frame 3 Unsnap the positive battery cable cover 4 Remove the negative and positive battery cables 5 Remove the retainer bolt and remove battery Installation Procedure 1 Install the battery in tray Notice Refer to Fastener Notice in Cautions and Notices 2 Install the battery retainer and tighten bolt Tighten Tighten retainer bolt to 25 Nem 18 Ib ft 3 Install the positive and negative cables and tighten Tighten Tighten cables to 17 N m 13 Ib ft Caution Do not let the battery posts touch the frame 4 Snapthe positive battery cable cover closed 5 Lift the battery tray 2 onto the bolts 1 on the frame and tighten 6 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure Relay Replacement 24V Generator Removal Procedure 1 Release the clip 2 securing the wiring harness to the underhood electrical center housing 2 Remove the 24V relay 1 from the underhood electrical center housing Engine Engine Electrical 6 35 3 Remove the connector position assurance CPA devices or secondary locks 4 Separate the relay 1 from the wiring harness connector 2 Installation Procedure 1 Connect the relay 1 to the wiring harness connector 2 2 Install any connector position assurance CPA devices or secondary locks 3 Install the 24V relay 1 onto the
26. Turn OFF the ignition Remove the negative cable from the frame mounted battery Pickup only Remove the battery negative cable from the right underhood battery Remove the negative cable of the 24V battery Remove the positive cable of the 24V battery 2004 LSSV Truck 6 38 Engine Electrical Engine 2004 LSSV Truck Installation Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices Notice Refer to Fastener Notice in Cautions and Notices Important Clean any existing corrosion from the battery terminal bolt flange and the battery cable end 1 Install the positive cable to the 24V battery 2 Install the battery ground negative cable to the 24V battery Tighten Tighten the bolt to 17 Nem 13 Ib ft 3 Install the negative battery cable to the right underhood battery Tighten Tighten the bolt to 17 Nem 13 Ib ft 4 Install the negative cable of the frame mounted battery Pickup only Tighten Tighten the bolt to 17 Nem 13 Ib ft Vehicle Load Disconnect Switch Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Caution and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure 2 Remove the disconnect switch key and the left upper brace 3 Remove the electrical center cover assembly 1 by lifting the cover outwards to clear the tabs 3 Engine Engine Electrical 6 39 4 Remove the switch mount
27. esn4 pejoeuuoosiq unim Bunsix3 LO 6a LO L3 uonnquisiq 69 ANd 0261 LHAW INd 80 9g 02 uan ejoH 80 punolg 6961 LHM 1d 80 ost 41d 8 0 2004 LSSV Truck Body and Accessories Lighting Systems 8 71 Component Locator Lighting Systems Component Views Rear Lamp Harness Legend 1 C908M 6 Military Trailer Connector 2 Auxiliary Rear Lamp Extension Harness 7 Military Trailer Connector 3 Rear of Vehicle 8 To Blackout B O Marker Lamp LH 4 Taillamp 9 G901M 5 To Blackout B O Marker Lamp RH 2004 LSSV Truck 8 72 Lighting Systems Body and Accessories Auxiliary Rear Lamp Harness Pickup Shown Utility Similar g EN GON Se Vm gt ui 75 SSS Legend 1 C908M 3 Wiring Harness 2 Auxiliary Rear Lamp Wiring Harness 2004 LSSV Truck Body and Accessories Lighting Systems 8 73 Forward Blackout B O Lamp Harness Legend 1 I P Wiring Harness 4 To Blackout B O Headlamp 2 Forward Lamp Wiring Harness 5 To Blackout B O Marker Lamp LF 3 Forward Lamp Harness Ground 6 To Blackout B O Marker Lamp RF 2004 LSSV Truck 8 74 Lighting Systems Body and Accessories Rear Blackout B O Lamps Pickup Legend 1 Rear Bumper 3 Blackout B O Lamp Assembly 2 Lamp Harness Connector 2004 LSSV Truck Body a
28. 1 to the blackout B O marker lamps 4 Connect the 3 blackout B O and the trailer harness connectors 2 5 Connect the 2 24V trailer harness connectors 5 to the 24V trailer harness 6 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 12V and 24V Harness Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Caution and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2 Disconnect the 12V and the 24V harness connector 1 from the blackout B O and the trailer harness connectors 3 Disconnect the license plate lamp connector 2 from the license plate lamp 4 Disconnect the blackout B O connector 3 from the blackout B O and trailer harness connector 5 Remove the 12V to 24V harness from the vehicle N e TY y Sr fi SE INT Sort YD V Ef 2004 LSSV Truck Body and Accessories Wiring Systems 8 53 Installation Procedure 1 Install the 12V to 24V wiring harness in the same routing location as removed 2 Connect the blackout connector 3 from the 12V and 24V harness to the blackout B O and trailer harness connector 3 Connectthe license plate lamp connector 2 from the 12V to 24V harness to the license plate lamp 4 Connect the 12V to 24V harness connector 1 to the blackout B O and the trailer harness connector 5
29. 2004 LSSV Truck Notice Do not use the jacknuts supplied in the kit Use rivnuts TX016183 instead Notice Refer to Fastener Notice in Cautions and Notices 3 Install the side rail over the adapter plates with the 2 outside bolts and the 2 upward facing bracket bolts and nuts Tighten Tighten the 2 outside bolts to 26 Nem 19 Ib ft Tighten the 2 upward facing bolts to 8 70 lb in Install side rail adapter plates front and rear by aligning the bolt holes to the holes in the box Install the troop seats Refer to Seat Replacement Troop in Seats Install the side struts top bows and cargo cover Refer to Cargo Cover Strut Replacement and Cargo Cover Top Bows Replacement Cargo Cover Front End Rail Replacement Removal Procedure Remove the cargo cover from the front of the cargo cover assembly Refer to Cargo Cover Replacement Remove the 4 bolts from the front end rails as needed Remove the 4 rivnuts by drilling out if damaged Body and Accessories Body Rear End 8 171 Installation Procedure 1 Apply 2 sided foam tape to the underside of the rails and to the edges of the mounting holes Notice Do not use the jacknuts supplied in the kit Use rivnuts TX016183 instead 2 Install the 4 rivnuts if damaged to the mounting holes using a rivnut installer Notice Refer to Fastener Notice in Cautions and Notices 3 Install the 2 front end rails to the front end of the box with
30. 24V OUTPUT CURRENT 40A MAX GROUND NEGATIVE S N 02000240 SURE POWER ea INDUSTRIES TUALATIN OREGON 97062 Made in USA The equalizer label is located on the side of the equalizer This label includes information on model number serial number and voltage specifications Vehicle Identification Plate U S PROPERTY NOMENCLATURE TRUCK LSSV MCTL MAKE AND MODEL CHEV2500HDCK25903 MFRS VIN 1GCHK24133E321226 REGISTRATION CURB WEIGHT MAX PAYLOAD GVWR GCWR 6860 LBS 2340 LBS 9200 LBS 22000 LBS DATE OF DELIVERY 10 08 03 WARRANTY 36 MONTHS 36 000 MILES ONTRACT NO GS 3QF K0002 RPNNL5086 PART NO 181623 The vehicle identification plate is located on the left front inner door panel under the shipping data plate This plate includes the identification number contract number and vehicle variant General Information Shipping Data Plate K25903HD SHIPPING DATA PLATE 2071 0 __ ne 1083 _ T VOLUME IH X W X LI The shipping data plate is located on the left front inner door panel above the vehicle identification plate This plate includes the loading and dimensions General Information 0 7 2004 LSSV Truck 0 8 General Information General Information BLANK 2004 LSSV Truck General Information Maintenance and Lubrication Maintenance Owner Checks and Services If the engine controls instruments or gages do not ope
31. 4 bolts over the 4 rivnuts Tighten Tighten the 4 bolts to 8 Nem 70 Ib in 4 Install the front of the cargo cover to the front end rail as needed Refer to Cargo Cover Replacement Cargo Cover Rear End Rail Replacement Removal Procedure 1 Remove the cargo cover from the end gate side of the cargo cover assembly Refer to Cargo Cover Replacement 2 Remove the 4 bolts from the end gate rail as needed 3 Remove the 4 rivnuts by drilling out if damaged Installation Procedure 1 Apply 2 sided foam tape to the underside of the rail and to the edges of the mounting holes Notice Do not use the jacknuts supplied in the kit Use rivnuts TX016183 instead 2 Install the 4 rivnuts if damaged to the mounting holes using a rivnut installer Notice Refer to Fastener Notice in Cautions and Notices 3 Install the end gate rail over the 4 rivnuts with 4 bolts Tighten Tighten the 4 bolts to 8 Nem 70 Ib in 4 Install the cargo cover to the rear end as needed Refer to Cargo Cover Replacement 2004 LSSV Truck 8 172 Body Rear End Body and Accessories 2004 LSSV Truck Cargo Cover Strut Replacement Removal Procedure Remove the cargo cover and top bows Refer to Cargo Cover Replacement and Cargo Cover Top Bows Replacement Remove the 3 front strut bolts holding the 3 side struts to the hinge bracket Remove the 6 nylock nuts Remove the 3 side struts with the 6 plastic bushings Replace if damage
32. B O service switch connector from the switch 3 2 Connecta test lamp at cavity C of the connector and ground Does the test lamp illuminate Go to Step 5 Go to Step 4 Replace the blackout service switch Did you complete the replacement Go to Step 9 5 Locate and repair the short to voltage on circuit 912 ORN Did you complete the repair Go to Step 9 m Remove the turn signal interrupt relay Do the turn signals operate Go to Step 8 Go to Step 7 Replace the turn signal interrupt relay Did you complete the replacement Go to Step 9 IS Locate and repair the short to voltage on circuit 639 PNK S Did you complete the repair Go to Step 9 Operate the system in order to verify the repair Did you correct condition System OK Go to Step 2 2004 LS SV Truck Body and Accessories Lighting Systems 8 97 Hi Beam Headlamps Operate in Blackout B O Mode Step Schem Action atic Reference Lighting Systems Schematics Yes No 1 Did you review Blackout B O Lighting Description and Operation 1 Place the blackout B O service switch in blackout B O mode 2 Connect a test lamp at cavity C of the blackout B O switch and ground Does the test lamp illuminate Go to Step 2 Go to Step 3 Go to Description and Operation Go to Step 6 1 Disconnect the blackout B O service switch connector from the switch 2 Connecta test lamp at cavity C of the connector and
33. Disconnect the blackout B O lamp 4 2 Connect a self powered test lamp at circuit 151 BLK and ground Does the test lamp illuminate Go to Step 6 Go to Step 5 Locate and repair open circuit 151 BLK between blackout 5 B O headlamp and G100M mu Did you complete the repair Go to Step 20 5 Replace blackout B O headlamp bulb Did you complete the replacement Go to Step 20 aH 1 Place blackout B O switch to ON position 2 Connecta test lamp at circuit 901 TAN WHT wire 7 between blackout B O drive relay cavity 85 and ground Does the test lamp illuminate Go to Step 8 Go to Step 9 SV Truck Body and Accessories Lighting Systems 8 87 Blackout B O Headlamp Inoperative cont d Step Action Locate and repair open in circuit 901 TAN WHT wire between blackout B O lamp cavity A and blackout B O drive relay cavity 85 Did you complete the repair Yes Go to Step 20 No Connect a test lamp at circuit 911 PNK wire between blackout B O drive relay cavity 87 and ground Does the test lamp illuminate Go to Step 10 Go to Step 11 10 Connect test lamp at circuit 915 WHT wire cavity 86 and cavity 87 of the blackout B O drive relay Does the test lamp illuminate Go to Step 13 Go to Step 15 11 Connect a test lamp from blackout B O service switch cavity A circuit 911 PNK and ground Does the test lamp illuminate Go to Step 12 Go to Step 14
34. Engine Electrical 24 Voltmeter Lamp Mounted in the accessory panel on the lower center of the I P Engine Electrical Component Views in Engine Electrical Engine Electrical Connector End Views in Engine Electrical Backup Lamp Relay Inline on the interrupt harness under the VP Blackout B O Drive Relay Inline on the auxiliary I P harness Engine Electrical Component Views in Engine Electrical Lighting Systems Connector End Views in Lighting Systems Blackout B O Headlamp On the left side of the bumper brush guard Lighting Systems Component Views in Lighting Systems Lighting Systems Connector End Views in Lighting Systems Blackout B O Marker Lamp LF In the left side of the front bumper Lighting Systems Component Views in Lighting Systems Lighting Systems Connector End Views in Lighting Systems Blackout B O Marker Lamp RF In the right side of the front bumper Lighting Systems Component Views in Lighting Systems Lighting Systems Connector End Views in Lighting Systems Blackout B O Service Switch In the accessory panel on center lower I P next to the 24V meter Lighting Systems Component Views in Lighting Systems Lighting Systems Connector End Views in Lighting Systems Blackout B O Stop Marker Lamp LR In the left side of the rear bumper Lighting Systems Component Views in Lighting Systems Lighting Systems Connector End View
35. Engine Electrical 6 33 Installation Procedure 1 Install the 12V 2 or 24V 3 circuit breaker to the fender support with the 2 bolts 1 Note Install 24V circuit breaker with auxiliary contact up 2 Install the wires to the circuit breaker with the two nuts 3 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure Circuit Breaker Bracket Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure 2 Remove the circuit breakers Refer to Circuit Breaker Replacement 12V or 24V 3 Remove the retainers 1 2 attaching the bracket 3 to the fender cowl support Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 1 Install the bracket 3 to the fender cowl support and tighten the retainers 1 2 Tighten Tighten bracket bolts to 6 Nem 53 Ib in 2 Install the circuit breakers Refer to Circuit Breaker Replacement 12V or 24V 3 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure 2004 LSSV Truck 6 34 Engine Electrical Engine 2004 LSSV Truck Battery Tray Battery Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure 2 Loosen the bolts 1
36. Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Military Trailer Connector Replacement Factory Bumper Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2 Disconnect the trailer harness connectors 2 3 3 Remove the fasteners securing the connector to the trailer hitch 4 Remove the cover 5 and trailer connector 4 Installation Procedure Note Connector harness depression is positioned at 3 o clock 1 Install the trailer connector 4 and cover 5 onto the trailer hitch Notice Refer to Fastener Notice in Cautions and Notices 2 Install the fasteners to secure the cover and connector to the bumper Tighten Tighten connector bolts to 5 Nem 44 Ib in 3 Connect the harness connectors 2 3 4 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2004 LSSV Truck 8 50 Wiring Systems Body and Accessories 2004 LSSV Truck Military Trailer Connector Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Disconnect the trailer harness connectors 1 Remove the fasteners securing the connector to the bumper Re
37. Refer to Battery Disconnect Caution in Caution and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2 Remove the positive cable 1 from the junction block 2 3 Remove the negative cable from the engine block 4 Remove any wiring harness straps securing the cable to the vehicle 5 Remove the bolt 3 and clamp 1 from the connector harness 2 6 Remove the bolts 1 from the winch connector 2 Note cable routing for installation 7 Remove connector harness from vehicle 2004 LSSV Truck Body and Accessories Wiring Systems 8 55 Installation Procedure 1 Install connector harness to the vehicle in the same routing as removed Notice Refer to Fastener Notice in Cautions and Notices 2 Position the connector 2 on the bumper and install bolts 1 Tighten the connector bolts to 5 8 Nem 44 71 Ib in 3 Install the clamp 1 onto the cables 4 Install the bolt 3 securing clamp to bumper Tighten Tighten the clamp bolt to 18 29 N m 13 21 Ib ft 5 Install the negative cable to the engine and the fastening bolt Tighten Tighten the negative cable bolt to 34 Nem 25 Ib ft 6 Install the positive cable 1 to the junction block 2 Tighten Tighten the junction block nut to 9 N m 80 Ib in 7 Install connector harness to vehicle in original location using wiring harness straps 8 Connect the battery cables Refer to Batter
38. Reinforcement Bar Repair Reinforcement Bar Replacement Maintenance 8 153 Relay Repair Relay Replacement 24V Generator 6 34 Relay Mounting Bracket Replacement 8 50 Schematics Engine Electrical sese eee eee 6 3 HONS sated eee Ate tev aay 8 123 Lighting SvSienma sse eee ee 8 61 WIG 8 3 Seats Description Folding Rear 8 158 Repair Seat Replacement Troop 8 157 Specifications Fastener Tightening Specifications 8 155 Shipping Data Repair Shipping Data Plate Replacement 8 160 Slave Receptacle Repair Slave Receptacle Replacement 8 138 Slave Receptacle Harness Repair Slave Receptacle Harness Replacement 8 57 Specifications Fastener Tightening Body Rear 8 167 n c ence trece cos 8 133 Engine 6 3 Exterior ere eie 03442 8 129 Frame and Underbody 8 179 Instrument Panel Gages and Console 8 117 Interior 8 159 8 61 Index Wiring Systems eee ee ee eee eee eee 8 3 Starting and Charging Component Views sese ee ee 6 11 Connector End
39. Topper Dome Lamp Bulb Replacement Removal Procedure 1 Press in on the sides of the lens to release the lens tabs 2 Remove the bulb from the lamp socket 2004 LSSV Truck 8 104 Lighting Systems Body and Accessories 2004 LSSV Truck Installation Procedure Important Use a standard 194 bulb for replacement 1 Install the bulb into the lamp socket 2 Install the lens into the lamp by pressing until fully seated Marker Lamp Replacement Rear Pickup Removal Procedure Caution Refer to Battery Disconnect Caution in Caution and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2 Remove the wiring harness strap from the marker lamp harness 3 Disconnect the marker lamp harness connector 1 by releasing the tab 4 Remove the nuts 2 and the ground connector 3 from the rear of the bumper 5 Remove the marker lamp 1 from the bumper Body and Accessories Lighting Systems 8 105 Installation Procedure 1 Position the marker lamp 1 onto the bumper Notice Refer to Fastener Notice in Caution and Notices 2 Install the nuts 2 and the ground connector 3 onto the mounting studs Tighten Tighten the nuts to 2 Nem 18 lb in 3 Connect the harness connector 1 to the marker lamp connector 4 Install the harness into the original mounting location using the wiring harness strap 5 Connect the battery cables R
40. Trailer Hitch Reinforcement Plate Replacement Maintenance Body in Frame and Underbody Reinforcement Bar Replacement Maintenance Body Removal Procedure 1 Remove the rear bumper Refer to Bumper Replacement Rear Maintenance Body 2 Remove the reinforcement bar bolts and reinforcement bar Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 1 Install the reinforcement bar and mounting bolts Tighten Tighten the reinforcement bar mounting bolts to 68 N m 50 Ib ft 2 Install the rear bumper Refer to Bumper Replacement Rear Maintenance Body 2004 LSSV Truck 8 154 Bumpers Body and Accessories Description and Operation Bumpers The equipment described includes all bumper assemblies front and rear that are offered for the military vehicles The bumper components provided in this military package are rugged and durable and are designed for the rigors of limited off road conditions Repairs on these items include the clevis tie down and pintle hooks The repair of some sub assemblies requires removal of the rear bumpers for access while others require removal of electrical components and lamp harness connections Winch Receiver The front and rear bumpers of some of the military vehicles are equipped with receivers For mounting of a portable winch the winch prep includes electrical connections for the winch 2004 LSSV Truck Body and Accessories Seats 8 155 Seats
41. ground Does the test lamp illuminate Go to Step 5 Go to Step 4 Replace the blackout B O service switch Did you complete the replacement Go to Step 9 Locate and repair the short to voltage on circuit 912 ORN Did you complete the repair Go to Step 9 Remove the backup lamp interrupt relay from the relay module Are the backup lamps illuminated Replace the backup interrupt relay Did you complete the replacement Go to Step 8 Go to Step 9 Go to Step 7 Locate and repair the short to voltage on circuit 1969 BLK WHT Did you complete the repair Go to Step 9 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 Low Beam Headlamps Operate in Blackout B O Mode Step Action Yes No Schem atic Reference Lighting Systems Schematics Did you review Blackout B O Lighting Description and Operation Go to Step 2 Go to Description and Operation 1 Place the blackout B O service switch in blackout B O mode 2 Connecta test lamp at cavity C of the blackout B O switch and ground Does the test lamp illuminate Go to Step 3 Go to Step 6 2004 LSSV Truck 8 98 Lighting Systems Body and Accessories Low Beam Headlamps Operate in Blackout B O Mode cont d 2004 LSSV Truck Step Action Yes No 1 Disconnec
42. i o dae tte die tees 8 127 Diagnosis Horns 8 125 Horns Operate Blackout Mode 8 126 Schematics eocena iio n a deer 8 123 Identification Cargo Carrier Base 0 3 Cargo Carrier Crew 0 3 Cargo Troop Carrier 0 3 Cargo Troop Carrier Crew 0 3 Utility ceno cete tec dera ipeo se 0 4 Identification Vehicle 0 3 Inline Harness Connector Views 8 29 Instrument Panel Gages and Console Description Instrument Panel and Gages Description 8 122 Repair Accessory Panel Replacement 8 119 Blackout Switch Replacement 8 121 Repair Voltmeter Replacement 8 119 Specifications Fastener Tightening Specifications 8 117 Interior Trim Description Interior 8 166 Repair Gun Rack Replacement Floor Mount Utility nerd Peotone Avice 8 163 Gun Rack Replacement Floor Mount etae iun etus cetus 8 162 Gun Rack Replacement Upper 8 164 Gun Rack Support Replacement Lower 8 164 Shipping Data Plate Replace
43. 12 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Bumper Replacement Front Utility Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2 Remove radiator grille brush guard Refer to Radiator Grille Brush Guard Replacement Utility 3 Remove the front grille Refer to Radiator Grille Replacement Utility in Exterior Trim 4 Remove front clevis Refer to Clevis Tie Down Replacement Front 5 Remove the blackout B O headlamp support from the bumper 6 Remove the retaining bolts 1 2 from the front bumper Remove the brace bolt 3 from the front bumper 8 Remove the front bumper assembly from the vehicle N 2004 LSSV Truck 8 138 Bumpers Body and Accessories 2004 LSSV Truck Installation Procedure 1 Position the front bumper assembly on the vehicle Notice Refer to Fastener Notice in Cautions and Notices Important Tighten the bolts in the following sequence 2 Install the retaining bolts 1 2 to the front bumper Tighten Tighten the bracket bolt 1 to 85 Nem 68 lb ft Tighten the bracket bolt 2 to 85 Nem 68 lb ft Tighten the brace bolt 3 to 55 Nem 41 lb ft Install the blackout B O headlamp support onto the bumper Install front clevis Refe
44. Circuit Operation Voltage is applied at all times to the horn relay through the 15A horn fuse in the underhood fuse block The blackout B O service drive switch is used to control the horn relay Power is applied through ORN circuit 40 to the blackout B O service drive switch which is normally a closed switch When the horn switch is depressed the horn switch contacts close providing a ground to the coil of the horn relay When the coil of the relay is grounded the relay energizes and the contacts close applying battery voltage directly to the LH and RH horn Because the horns are grounded at ground G100 the horns will sound as long as the horn switch is depressed The blackout B O service drive switch is used to disable the horn relay when placed in the blackout B O mode When the blackout B O service drive switch is in the ON position power to the horn relay is disrupted leaving the horns inoperative 2004 LSSV Truck 8 128 Horns Body and Accessories BLANK 2004 LSSV Truck Body and Accessories Exterior Trim 8 129 Exterior Trim Specifications Fastener Tightening Specifications Specification Application Metric English Mud Flap Brace Bolts 25 Nem 18 Ib ft Mud Flap Screws 4 35 Ib in 2004 LSSV Truck 8 130 Exterior Trim Body and Accessories 2004 LSSV Truck Repair Instructions Rear Mud Flap Replacement Removal Procedure Caution Refer to Vehicle Lifting Ca
45. Inline Harness Connector End Views C909M 1 Cavity Rear bumper for blackout B O relay Inline Harness Connector End Views C910M 1 Cavity Utility Rear bumper for license lamp Inline Harness Connector End Views C911M Rear bumper for trailer connector 2004 LSSV Truck Body and Accessories Wiring Systems 8 15 Master Electrical Component List cont d Name Location Locator View Connector End View G100M In the front blackout B O harness front of Power and Grounding vehicle Component Views p G101M In the 24V generator harness G103M Right side of engine block v G104M Left side of bulkhead next to the power brake booster G105M Left side of bulkhead next to the power brake booster G301M Right outer side of frame rail G304M Under left side of UP a C G901M In the rear blackout B O harness at the Power and Grounding rear of the vehicle Component Views G902M Right side of the rear bumper mE m G903M Left side of the rear bumper m mE S100M In front bracket wiring harness behind front bumper 102M In the front blackout B O harness at front bumper I S104M In the 24V generator harness in the engine compartment EI S105M In the 24V generator harness in the engine compartment S106M In the relay block harness next to the Underhood fuse block gt m 5107 In the
46. Lamps Always On 8 92 Blackout B O Marker Lamps Inoperative 8 91 Blackout Stoplamps Inoperative 8 90 CTSY Lamps Operate in Blackout B O i di e e d E ETUR 8 95 DRL Operate in Blackout Mode 8 93 Headlamps Operate in Blackout B O MOGG iui eta Siete tart id e T 8 88 Hi Beam Headlamps Operate in Blackout Mode sss sese 8 97 Low Beam Headlamps Operate in Blackout B O Mode aerae tae d aree 8 97 Park Lamps Operate in Blackout B O iddia aaia 8 94 Turn Signals Operate Blackout t ce a 8 96 Function Tables sees eee ee eee 8 115 Repair Headlamp Bulb Replacement Blackout B O AE dede eee 8 100 Headlamp Replacement Blackout B O PICKUP meretur eus 8 99 Headlamp Replacement Blackout B O OMY ette 8 99 Lamp Replacement Voltmeter 8 107 License Plate Bracket Replacement E E rettet 8 111 License Plate Lamp Replacement PICKUP ti ett siet bees 8 109 License Plate Lamp Replacement Utility 8 111 Marker Lamp Replacement Front Blackout Pickup 8 101 Marker Lamp Replacement Front Blackout Utility 8 102 Marker Lamp Replacement Maintenance BOO o eoi Force ERO ES 8 109 Ma
47. Lamps Inoperative cont d Step Action Yes No Locate and repair an open in circuit 911 PNK wire between 10 inline fuse B and blackout service drive switch Did you complete the repair Go to Step 18 Disconnect the blackout B O marker lamp s and connect a test lamp between cavity A circuit 900 BRN WHT front and 11 circuit 900 BRN WHT rear to ground Does the test lamp illuminate Go to Step 12 Go to Step 13 Replace blackout B O marker lamp s assembly Did you complete the replacement Go to Step 18 Locate and repair an open in circuit 900 BRN WHT front and circuit 900 BRN WHT rear wire between inline fuse and 13 blackout marker lamp assembly gt Did you complete the repair Go to Step 18 Connect a test lamp between the blackout B O service 14 switch to circuit 40 ORN cavity B and ground Does the test lamp illuminate Go to Step 15 Go to Step 16 Replace the blackout B O service switch Did you complete the replacement Go to Step 18 Connect a test lamp at I P relay block connector C8 cavity 16 Circuit 40 ORN wire and ground Belang the C K Truck Service Does the test lamp illuminate Go to Step 17 Manual Locate and repair open in circuit 40 ORN wire between I P relay block connector C8 cavity C and the blackout B O 17 service drive switch Did you complete the repair Go to Step 18 38 Operate the system in ord
48. Operation 3 4 Tires and 5 annern nenene nnnenn nnn 3 4 2004 LSSV Truck 3 2 Table of Contents Suspension BLANK 2004 LSSV Truck Suspension Tires and Wheels Repair Instructions Tire Hoist Shaft Extension Replacement Removal Procedure 1 Remove the spare wheel storage lock cylinder if equipped Refer to Changing a Flat in the 2004 C K Truck Owner s Manual Remove the spare tire Refer to Tire Hoist and Shaft Replacement in Tires and Wheels in the 2004 C K Truck Service Manual Pull the retainer clip and remove the pin Remove the tire hoist shaft extension Installation Procedure Install the tire hoist shaft extension and align Install the retainer clip and pin Install the spare tire Refer to Tire Hoist and Shaft Replacement in Tires and Wheels in the 2004 C K Truck Service Manual Install the spare wheel storage lock cylinder if equipped Refer to Changing a Flat in the 2004 C K Truck Owner s Manual Tires and Wheels 3 2004 LSSV Truck 3 3 4 Tires and Wheels Suspension Description and Operation Tires and Wheels Spare Wheel Hoist Shaft The spare tire is located under the rear end of the pickup and utility models The hoist shaft allows a link between the tire hoist and the military rear bumper The factory spare tire hoist tools are used to remove the spare An access hole in the rear of the bumper is provided to allow access If
49. Power Converter Brush Guard 2004 LSSV Truck 0 6 General Information Labels Your vehicle may have some or all of the following labels Vehicle Load Disconnect Switch Caution Label 12 VOLT 24 VOLT VEHICLE LOAD DISCONNECT SWITCH MAIN BATTERY FEEDS TO STARTER WINCH amp NATO JUMP START CONNECTOR REMAIN POWERED This switch disconnects 12 volt vehicle loads amp 24 volt trailer aux loads that could cause parasitic drain on batteries z 5 Notice The main battery feeds to starter and NATO jump start connector remains powered If the vehicle is equipped with a load disconnect switch the switch disconnects 12 volt vehicle loads and 24 volt trailer aux loads that could cause a parasitic drain on the batteries The switch should be placed in the OFF position when the vehicle is parked for an extended period of time The load disconnect switch is located on the underhood fuse block The underhood fuse block is located on the driver s side of the vehicle to the rear of the battery 24V Battery Caution Label 12 VOLTS 24 VOLTS CAUTION BATTERY 24 VOLTS DO NOT GROUND TERMINALS PART NO TX016079 The 24V battery caution label is placed on top of the radiator support near the 24V battery This battery is on the left side of the engine compartment 2004 LSSV Truck General Information Equalizer Label EQUALIZER MODEL 41204 INPUT VOLTAGE 12V OUTPUT VOLTAGE
50. accessory panel Refer to Accessory Panel Replacement in Instrument Panel Gages and Console Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Lighting Systems 8 11 2004 LSSV Truck 3 8 114 Lighting Systems Body and Accessories Description and Operation Blackout B O Lighting Circuit Operation Voltage for connector C8 the blackout B O marker lamps is supplied through the accessory voltage circuit YEL 243 located in the I P relay center From there the ORN 40 wire supplies voltage to the blackout B O service switch When the blackout B O service switch is placed in blackout B O mode voltage is applied to the PNK 911 wire to inline 5A fuse Voltage is then applied to the BRN WHT 900 wire for front blackout B O marker lamps and BRN WHT 900 wire for rear blackout B O marker lamps Ground for the front blackout B O marker lamps is supplied through G100M for the front and G903M and G902M for the rear The blackout B O stoplamps voltage is supplied through the stop LP fuse ORN 1540 wire to the TCC stoplamp switch at all times When the brake pedal is depressed the stoplamp switch is closed and powers the WHT 17 wire to the blackout B O service switch When in blackout B O mode voltage is applied from the DK GRN WHT 902 wire to the blackout B O stoplamps The blackout B O stoplamps receive constant ground through G903M and G902M
51. at G200 through the I P relay block Color graduations as viewed from the front of the meter from left to right are as follows e Minimum voltage to activate the pointer 18 0 volts e Red Yellow Break Point 22 0 volts e Yellow Green Break Point 26 0 volts e Small Hack Mark in green 28 5 volts 2004 LSSV Truck In a no load situation with the engine OFF the gage needle should be mid way between the red band and green band in the yellow band If the gage needle is in the lower end of the yellow band this is unacceptable and the battery may be weak Body and Accessories Table of Contents 8 1 Section 8 Body and Accessories Wiring Systems 8 3 Specifications eese 8 3 Schematic and Routing Diagrams 8 3 Component 8 12 Master Electrical Component List 8 12 Power and Grounding Component Views 8 17 Electrical Center Identification Views 8 28 Inline Harness Connector End Views 8 29 Repair Instructions eee 8 45 Auxiliary Lamp Harness Replacement ErOnti etum eh ice e ted EL 8 45 Auxiliary Lamp Extension Harness Replacement 8 46 Lamp Harness Replacement Rear 8 47 Commercial Trailer Connector Repl
52. of the inoperative lamp for high resistance or an open Refer to Circuit Testing and Wiring 9 Repairs in Wiring Systems in the 2004 C K Truck Service Manual Did you find and correct the condition Go to Step 15 Go to Step 14 Using a fused jumper connect cavity D to cavity F of the 10 blackout service lamp switch connector Do the brake lamps illuminate Go to Step 11 Go to Step 12 Replace blackout B O service lamp switch Did you complete the replacement Go to Step 15 nm Connect a test lamp between terminal A of the rear blackout 12 B O stoplamps and ground Did the test lamp illuminate Go to Step 14 Go to Step 13 D Locate and repair the open or high resistance in circuit 902 Did you correct the condition Go to Step 15 m 2004 LS SV Truck Body and Accessories Lighting Systems 8 91 Blackout B O Stoplamps Inoperative cont d Step Action Yes No T Replace the blackout B O stoplamp s Did you complete the replacement Go to Step 15 ZEN i Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 Blackout B O Marker Lamps Inoperative Step Action Yes No Schematic Reference Lighting Systems Schematics 1 Did you review Blackout B O Lighting Description and Go to Description Operation Go to Step 2 and Operation Verify that the marker lamps are inoperative Go to Testing for Do the marker
53. sliding on the stud Notice Refer to Fastener Notice in Cautions and Notices 4 Install the washer and nut 3 to the lamp stud Tighten Tighten the nut to 10 N m 89 Ib in Headlamp Replacement Blackout B O Utility Removal Procedure 1 Remove the radiator grille brush guard Refer to Radiator Grille Brush Guard Replacement Utility in Bumpers 2 Remove upper grille baffle 3 Remove radiator grille 4 Remove the nut 2 and washer from the lamp stud at the base of the mounting bracket 5 Remove the ground lead by sliding it off the stud 6 Disconnect the auxiliary wiring harness lead from headlamp 7 Remove the blackout B O lamp assembly from the mounting bracket 2004 LSSV Truck 8 100 Lighting Systems Body and Accessories 2004 LSSV Truck Installation Procedure 1 Install the blackout lamp assembly to the mounting bracket 2 Connect the auxiliary wiring harness connector 1 3 Install the ground lead by sliding on the stud Notice Refer to Fastener Notice in Cautions and Notices 4 Install the washer and nut 2 to the lamp stud Tighten Tighten the nut to 10 N m 89 Ib in 5 Install the radiator grille 6 Install upper grille baffle 7 Install the radiator brush guard Refer to Radiator Grille Brush Guard Replacement Utility in Bumpers Headlamp Bulb Replacement Blackout B O Removal Procedure 1 Remove the screws 1 holding the lens
54. the circuit breakers These step the power down from 24V to 12V Greater power is needed for the higher load used by optional radio communications or for compatibility with other slave receptacles on other vehicles Refer to in the 2004 C K Truck Service Manual for further details Refer to replacement procedures in this manual for repairs on various electrical components Maintenance The 24V power system makes each vehicle capable of accepting a power boost through its slave receptacle from any vehicle similarly equipped This 24V system requires specific maintenance Note Repairs in this manual are limited to the specific military equipment included in the LSSV options most commonly ordered Charging System Description and Operation Charging Pickup The LSSV pickup vehicles are equipped with a 24V generator The 24V generator s electronics are isolated from the chassis ground The 24V configuration provides sufficient capacity and reserve for 24V loads Electrical loads can be connected indefinitely while the engine is running and for a limited time when engine is OFF The 24V battery must be above 7 volts in order for the generator to turn ON The generator features permanently lubricated bearings Service should only include the tightening of mounting components Otherwise the generator is replaced as a complete unit Utility The LSSV utility vehicles are equipped with a DC to DC power converter The primary function o
55. the 24V relay Refer to Relay Replacement 5 24V Generator Did you complete the replacement Repair the 24V relay ground control circuit for an 6 open or high resistance Did you complete the repair Operate the system in order to verify the repair Did you correct the condition Battery Inspection Test 24V FE Connect a test lamp between terminal 86 and 12 ground Did the test lamp illuminate Go to Step 16 Goto Step 14 2004 LSSV Truck 6 28 Engine Electrical Engine Power Converter Inoperative Utility Power Converter Inoperative Utility Step Action Yes No Schematic Reference 24V Power Converter Schematics 1 Did you review the Charging System Description and Go to Description Operation Go to Step 2 and Operation Are the batteries properly charged Go to Battery Charging in Non 2 HP2 in Engine Electrical of the 2004 C K Truck Go to Step 3 Service Manual 5 Connect a test lamp between the shorter 12V stud and ground Does the test lamp illuminate Go to Step 4 Go to Step 5 P Connect a test lamp between the shorter 24V stud and ground Does the test lamp illuminate Go to Step 11 Go to Step 9 5 Connect a test lamp between the longer 12V stud and ground Does the test lamp illuminate Go to Step 6 Go to Step 7 Locate and repair the source of the overload and replace the 6 fuse Refer to 24V Converter Fuse Replacement Di
56. the blackout B O switch and ground Does the test lamp illuminate Go to Step 3 Go to Step 6 1 Disconnect the blackout B O service switch connector form the switch 3 2 Connect a test lamp at cavity C of the connector and ground Does the test lamp illuminate Go to Step 5 Go to Step 4 Replace the blackout B O service switch Did you complete the replacement Go to Step 9 2208 Locate and repair the short to voltage on circuit 912 ORN Did you complete the repair Go to Step 9 Remove the backup lamp interrupt relay from the relay 6 module Are the backup lamps illuminated Go to Step 8 Go to Step 7 7 Replace the backup interrupt relay Did you complete the replacement Go to Step 9 Locate and repair the short to voltage on circuit 24 8 GRN BLK Did you complete the repair Go to Step 9 5 Operate the system in order to the repair Did you correct the condition System OK Go to Step 2 Park Lamps Operate in Blackout B O Mode Step Action Yes No Schematic Reference Lighting Systems Schematics 1 Did you review Blackout B O Lighting Description and Go to Description Operation Go to Step 2 and Operation 1 Place the blackout B O service switch in blackout B O mode 2 2 Connect a test lamp at cavity C of the blackout B O switch and ground Does the test lamp illuminate Go to Step 3 Go to Step 6 2004 LSSV Truck Body and Acc
57. the engine Verify that the vehicle charging system is operating correctly Refer to Charging System Test CS AD SI Generators in Engine Electrical of the 2004 C K Truck Service Manual Using a DMM verify that 12V is present at the IGN terminal 1 of the converter Apply 10 amps of 24V load Using a DMM measure the 12V input voltage 2 and the 24V output voltage 3 The 24V output voltage should be two times the 12V input voltage 0 3 volts If the voltage is not within the voltage value replace the converter Refer to Power Converter Replacement Utility 2004 LSSV Truck Engine Engine Electrical 6 31 Repair Instructions Jump Starting in Case of Emergency If the battery or batteries on the vehicle has run down and the vehicle will not start you may want to use another vehicle to provide power to start the vehicle The NATO term for this system is slave receptacle In the event the system must be replaced refer to Slave Receptacle Replacement in Bumpers NATO Slave Cables are the only recommended method of jump starting similar vehicles Slave Starting Caution Batteries can hurt you They can be dangerous because they contain acid that can burn you They contain gas that can explode or ignite They contain enough electricity to burn you If you don t follow these steps exactly some or all of these things can hurt you Notice Ignoring these steps could result in costly damage to the vehicle Trying to sta
58. the ground circuit 150 of the voltmeter for an open or for a 4 high resistance Did you find and correct the condition Go to Step 6 Go to Step 5 Replace the voltmeter Refer to Voltmeter Replacement in 5 Instrument Panel Gages and Console Did you complete the replacement Go to Step 6 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 2004 LS SV Truck Engine Engine Electrical 6 25 24V Generator Noise Diagnosis Diagnostic Aids Noise from a generator may be due to electrical or mechanical noise Electrical noise or magnetic whine usually varies with the electrical load placed on the generator and is a normal operating characteristic of all generators When diagnosing a noisy generator it is important to remember that loose or misaligned components around the generator may transmit the noise into the passenger compartment and that replacing the generator may not solve the problem 24V Generator Noise Test the generator for proper operation using the generator tester Refer to Charging System Test in Engine Electrical in 2004 C K Truck Service Manual Is the generator operating properly Go to Step 2 Go to Step 10 Start the engine Verify that the noise can be heard Turn OFF the engine Disconnect the 4 way connector from the generator Start the engine Listen for the noise Has the noise stopped Go to Step 10 Go to Step 3 Turn OFF the en
59. time 3 Install the 3 bumper reinforcement to frame nuts bolts Notice Refer to Fastener Notice in Cautions and Notices Important Tighten the rear bumper reinforcement in the following sequence Tighten Tighten the 3 bumper reinforcement to frame nuts bolts to 117 Nem 87 lb ft Tighten the 2 side bumper reinforcement bracket bolts nuts to 79 Nem 59 Ib ft Note Repeat for opposite side reinforcement Bumper Replacement Rear Utility Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2 Disconnect the blackout B O marker lamps connector 2 by depressing the tab releases and remove the ground leads 1 from mounting stud 3 Disconnect the trailer lamp connectors 2 3 by depressing the tab releases 2004 LSSV Truck 8 146 lt 2004 LSSV Truck Body and Accessorie 4 Remove pintle hook from the receiver Remove the lower step pad Remove lower bolts attaching bumper to receiver Remove the bolts and nuts holding the rear bumper to the brace s at the lower attaching points Remove the bolts and nuts holding the rear bumper to the brace s at the upper attaching points Remove the bolts washers and nuts holding the rear bumper to the frame rail Remove the rear bumper 1 Installation Procedure Install th
60. x EYE EXE ERE RENE 8 159 Specifications essere 8 159 Repair Instructions eee 8 160 Government Vehicle Data Plate Replacement eese 8 160 Shipping Data Plate Replacement 8 160 Floor Mat Replacement 8 161 Gun Rack Replacement Floor Mount Crew zi en rire neris 8 162 2004 LSSV Truck Gun Rack Replacement Floor Mount Utility etit pin eti 8 163 Gun Rack Support Replacement Lower 8 164 Gun Rack Replacement Upper 8 164 Description and Operation 8 166 Interior Description 8 166 Body Rear 8 167 Specifications eese 8 167 Repair Instructions eee 8 168 Fiberglass Top Replacement 8 168 Cargo Cover Side Rail and Hinge Replacement esee 8 168 Cargo Cover Front End Rail Replacement 8 170 Cargo Cover Rear End Rail Replacement 8 171 Cargo Cover Strut Replacement 8 172 Cargo Cover Top Bows Replacement 8 172 Cargo Cover Replacement 8 173 Cargo Cover Stowage Replacement 8 174 Maintenance Body Replacement 8 174 Description and Operation
61. 081 e 12129155 Connector Part Information e 2 Way F Flex Lock 280 Connector Part e 2 Way M M P 280 Series Series BLK information BLK Wire Circuit Wire Circuit Color No Function Pin Color No Function A WHT 17 Brake Light Switch A WHT 17 Blackout B O Service Switch B Not Used B Not Used 2004 LSSV Truck 3 8 34 Wiring Systems Body and Accessorie Inline Harness Connector C304M um A 10547 10547 e 02984883 Connector Part 2 Nav M Series 280 Information e 2 Way F Series 280 BLK Information BLK Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function BRN 8008 Voltmeter Supply BRN 8008 Voltmeter Supply Voltage Pickup Voltage Pickup ORN 901 Voltmeter Supply ORN 901 Voltmeter Supply Voltage Utility Voltage Utility B BLK 150 Ground B BLK 150 Ground Inline Harness Connector C305M Jk 14637 Ag 14636 e 12129081 e 12129155 Connector Part Connector Part 2 Way F Flex Lock 280 e 2 Way M M P 280 Series Information Series BLK Information BLK A Wire Circuit 7 Wire Circuit Color No Function Pin Color No Function A GRY BLK 690 CTSY Supply Voltage A GRY BLK 690 CTSY Supply Voltage B ORN BLK 1732 Inadvertent Power B ORN BLK 1732 Inadvertent Power Supply Voltage Su
62. 1 Ensure that the headlamp switch is in the OFF position Using your hands peel the rubber gasket away from the sides of the lens Lift the lens off the lamp assembly Remove the bulb from the socket m gt Installation Procedure Important Use the following bulbs for replacement e Park stoplamp 1157 e Turn signal 1156 e Backup lamp 1156 1 Install bulb into the lamp socket 2 Install the lens into the lens gasket Important Ensure that the lens is fully installed in the gasket Body and Accessories Lighting Systems 8 109 Marker Lamp Replacement Maintenance Body Removal Procedure Important The bulbs in the marker lamps are not replaceable and are serviced as an assembly 1 Ensure that the headlamp switch is in the OFF position 2 Using your hands peel the lens out of the rubber gasket 3 Disconnect the wire harness from the back of the lens 15684 Installation Procedure 1 Connect the wire harness onto the lamp 2 Install the lens into the rubber gasket 3 Ensure that the lens is fully installed in the gasket 15684 License Plate Lamp Replacement Pickup Removal Procedure 1 Ensure the headlamp switch is in the OFF position 2 Remove the bulb socket 2 and bulb from the back of the lamp 2004 LSSV Truck 8 110 Lighting Systems Body and Accessories 3 Slide the retainer clip 1 off of the license plate lamp 2 4 Remove the license plate lamp 2 from the bumper Installation
63. 1 Install the receiver 2 on the vehicle and loosely install the bolts 1 in the frame 2 Loosely install the bolts 3 in the bumper Notice Refer to Fastener Notice in Cautions and Notices 3 Tighten the receiver bolts 1 and 3 Tighten Tighten the bolts to 125 Nem 92 Ib ft 4 Install the clevis mounts Refer to Clevis Tie Down Bracket Replacement Rear Utility in Bumpers 5 Install the hitch in the receiver Trailer Hitch Reinforcement Plate Replacement Maintenance Body Removal Procedure 1 Remove the pintle hook from the trailer hitch 2 Remove the bolts from the tie down plate 3 Remove the trailer hitch and reinforcement plate from the vehicle 2004 LSSV Truck 8 182 Frame and Underbody Body and Accessories Installation Procedure 1 Position trailer hitch and reinforcement plate to the vehicle Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts to the tie down plates Tighten Tighten the hitch mounting bolts to 117 Nem 87 lb ft 3 Install the pintle hook 2004 LSSV Truck Body and Accessories Frame and Underbody 8 183 Description and Operation Frame and Underbody Description Hitch Receiver Utility Hitch receiver is frame mounted The receiver will allow use of different components such as a pintle hook or a multi mount winch The military hitch receiver is accessible through the rear bumper to accommodate a higher trailer torque height Hitch
64. 3 Install the bolts in the mount and tighten Tighten Tighten the rear bolts to 8 Nem 70 Ib in Tighten the front bolts to 55 41 Ib ft Gun Rack Replacement Floor Mount Utility Removal Procedure 1 Remove bolts securing gun rack to the floor 2 Remove the gun rack 1 from vehicle Installation Procedure 1 Install the gun rack 1 and slide under the front seat bolts Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts in the mount and tighten Tighten Tighten the rear bolts to 8 Nem 70 Ib in 2004 LSSV Truck 8 164 Interior Trim 2004 LSSV Truck Body and Accessories Gun Rack Support Replacement Lower Removal Procedure 1 Remove the 2 bolts 1 holding the support to the floor 2 Remove the support 2 Installation Procedure 1 Install the support 2 by aligning the bolts holes Notice Refer to Fastener Notice in Cautions and Notices 2 Install the 2 bolts 1 holding the support to the floor and tighten Tighten Tighten the 2 bolts to 8 Nem 70 Ib in Gun Rack Replacement Upper Removal Procedure 1 Remove the lower rear window molding Refer to Molding Replacement Rear Window Lower in Interior Trim in the 2004 C K Truck Service Manual 2 Remove the bolts 1 holding the upper mount to the inner body 3 Remove the upper gun rack 2 Body and Accessories Interior Trim 8 165 Installation Procedure
65. 3 to frame Notice Refer to Fastener Notice in Cautions and Notices Notice Clevis must move once torqued Do not over torque 2 Install the bolt 2 and nut 1 and tighten Tighten Tighten the nut and bolt to 200 N m 148 Ib ft 2004 LSSV Truck Body and Accessories Bumpers 8 151 Bumper Replacement Rear Maintenance Body Removal Procedure Caution Refer to Battery Disconnect Caution in Caution and Notices 1 2 3 10 11 12 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Remove the clevis tie down Disconnect the trailer wiring harness Refer to Blackout B O and Trailer Harness Replacement Rear in Wiring Systems Remove the winch connector if equipped Refer to Winch Connector Harness Replacement Rear in Wiring Systems Remove the 4 bumper bolts 1 right side shown left side similar Using the aid of an assistant remove the rear bumper from the vehicle by sliding it off the brackets Remove the trailer wiring harness from the rear bumper Refer to Blackout B O and Trailer Harness Replacement Rear in Wiring Systems Remove the marker lamps Refer to Marker Lamp Replacement Maintenance Body in Lighting Systems Remove the taillamps Refer to Taillamp Replacement Maintenance Body in Lighting Systems Remove the blackout B O marker lamps Refer to Marker Lamp Replacement Rear Maintenance Body i
66. 7 GRY BLK 2226 Dimmer Switch 7 GRY BLK 2226 Dimmer Switch Signal from BCM Signal from BCM 2004 LSSV Truck S ody and Accessories Wiring Systems 8 37 Inline Harness Connector C308M p pu 14637 14636 e 12129081 e 12129155 Connector Part Connector Part e 2 Way F Flex Lock 280 e 2 Way M M P 280 Series Information Series BLK Information BLK Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function A ORN 912 Blackout B O A ORN 912 Blackout B O Service Switch Service Switch Voltage Voltage B BLK 150 Ground B BLK 150 Ground Inline Harness Connector C900M 000 B G B A 10581 10582 e 12010717 e 12015793 Connector Part Connector Part x e 3 Way F Weather Pack e 3 Way M Weather Information TWR BLK Information TWR BLK Wire Circuit Wire Circuit x Pin Color No Function Pin Color No Function BRN 30 Blackout B O BRN 30 Blackout B O Marker Lamps Marker Lamps Pickup A Pickup BRN WHT 900 Blackout B O BRN 900 Blackout B O Marker Lamps Marker Lamps Utility Utility B YEL 18 S T Lamp Feed Left B YEL 18 S T Lamp Feed Left BLK 150 Ground C BLK 150 Ground 2004 LSSV Truck 8 38 Wiring Systems Body and Accessorie Inline Harness Connector C901M QQ B C C B A 10581 10582 e 12010
67. 717 e 12015793 Connector Part Connector Part e 3 Way F Weather Pack 3 Way M Weather Information SHD BLK Information SHD BLK Wire Circuit Wire Circuit z Pin Color No Function Pin Color No Function A BRN 9 Park Lamp Feed A BRN g Park Lamp Feed GRN 30 Blackout B O DK GRN 30 Blackout B O Stoplamps Pickup B Stoplamps Pickup GRN WHT 902 Blackout B O DK GRN 902 Blackout B O Stoplamps Utility Stoplamps Utility C DK GRN 19 S T Lamps Right C DK GRN 19 S T Lamps Right Inline Harness Connector C902M 55 10572 10571 e 12015792 e 12010973 ds e 2 Way F Weather Pack n e 2 Way M Weather Pack TWR TWR BLK Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function A GRN WHT 902 Right Rear Blackout B O Stoplamps GRN WHT 902 Right Rear Blackout B O Stoplamps BRN WHT 900 Right Rear Blackout B O Marker Lamps B BRN WHT 900 Right Rear Blackout B O Marker Lamps 2004 LSSV Truck S B ody and Accessories Wiring Systems 8 39 Inline Harness Connector C903M B A 10573 10574 e 12015792 e 12010973 e 2 Way F Weather Pack prose Ba e 2 Way M Weather Pack TWR BLK SHD BLK Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function A GRN WHT 902 Left Rear Blackout A GRN WHT 902 Left Rear Bl
68. 99 Headlamp Bulb Replacement Blackout B Q s iii t en ier Ee RE e E eas 8 100 Marker Lamp Replacement Front Blackout Pickup 8 101 Marker Lamp Replacement Front Blackout Utility 8 102 Topper Dome Lamp Bulb Replacement 8 103 Marker Lamp Replacement Rear PICKUP vets eC 8 104 Marker Lamp Replacement Rear dE 8 105 Lamp Replacement Voltmeter 8 107 Taillamp Replacement Maintenance 8 107 Taillamp Bulb Replacement Maintenance iin d teda 8 108 Marker Lamp Replacement Maintenance BOY ia e 8 109 License Plate Lamp Replacement PICKUP is techo eet rete tee 8 109 License Plate Lamp Replacement Utility 8 111 License Plate Bracket Replacement cii oen RE RE e 8 111 Topper Dome Lamp Switch Replacement pii P 8 112 Topper Dome Lamp Switch Replacement tr ette tete itr e Rr IDEEN 8 113 Description and Operation 8 114 Blackout B O Lighting Circuit Operation 8 114 Function Tables sse eee eee 8 115 Instrument Panel Gages and Console 8 117 Specifications eese 8 117 Repair Instructions eee 8 119
69. Body and Accessories Wiring Systems 8 31 Inline Harness Connector C105M A B B A gt 10792 10791 e 12129136 e 12129135 Connector Part Connector Part e 4 Way F Flex Lock 280 4 Way M M P 280 Series Information Series BLK Information BLK Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function A WHT 1080 Park Lamps Supply A WHT 1080 Park Lamps Supply Voltage Voltage B BLK WHT 1969 Head Lamps Hi B BLK WHT 1969 Head Lamps Hi Beam Supply Beam Supply Voltage Voltage C PNK WHT 1970 Head Lamp Low C PNK WHT 1970 Head Lamp Low Beam Supply Beam Supply Voltage Voltage D PNK 639 Turn Signals Supply D PNK 639 Turn Signals Supply Voltage Voltage Inline Harness Connector C106M C 14632 14633 e 12129489 e 12129490 Connector Part Connector Part e 3 Way M P Flex Lock e 3 M P 280 Series Information 280 Series BLK Information BLK Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function A LT 592 DRL Supply Voltage A LT 592 DRL Supply Voltage GRN BLK GRN BLK B DK GRN 1329 Horn Supply Voltage B DK GRN 1329 Horn Supply Voltage ORN 340 Radio Supply Voltage C ORN 340 Radio Supply Voltage 2004 LSSV Truck 8 32 Wiring Systems Inline Harness Connector C107M Body and Accessorie 10561 10565 Connector Part 12015791 1 Way F Weather Pack C
70. Bracket Replacement Circuit Breaker Replacement 12V or 24V Clevis Tie Down Repair Clevis Tie Down Bracket Replacement Rear Clevis Tie Down Replacement Front 6 33 6 32 2004 LSSV Truck Clevis Tie Down Replacement Front Utility een tba eet is 8 141 Clevis Tie Down Replacement Rear Utility ve tette 8 150 Clevis Tie Down Replacement Rear Military 8 149 Clevis Tie Down Support Replacement Front Utility 8 142 Commercial Trailer Connector Replacement 8 48 CTSY Lamps CTSY Lamps Operate in Blackout B O 8 95 DRL Operate in Blackout Mode 8 93 E Electrical Center Identification Views 8 28 Engine Electrcial Components Starting and Charging Component Views 6 11 EE 6 20 Description Battery 12V and 24 6 43 Charging System Description and Operation iei reden 6 43 Diagnosis 24V Generator Inoperative Pickup 6 26 24V Generator Noise Diagnosis 6 25 Battery Inspection Test 24V 6 27 Power Converter Inoperative Ultility 6 28 Power Converter 6 30 Voltmeter Inaccurate or Inoperative PICKUP der D axe t idea 6 24 Voltmeter
71. Caution and Notices 2 Loosely install the maintenance body fasteners to the frame rails Tighten Tighten the retaining bolts to the frame rail to 85 Nem 63 Ib ft 3 Connect the fuel fill and vent hoses to the fuel fill bucket 4 Install the rear bumper assembly Refer to Bumper Replacement Rear Maintenance Body in Bumpers 5 Connect the wiring harness for the maintenance body 6 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2004 LSSV Truck 8 176 Body Rear End Body and Accessories Description and Operation Body Rear End The pickup vehicle is equipped with several military options including a cargo cover troop seats left and right fiberglass top and maintenance body Cargo Cover The cargo cover is a rain resistant canvas top cover supported by bows and siruts and attached by rails to the cargo box It can be held down with hooks and buckles or velcroed closed It may also be rolled up and secured with straps or folded and stowed while not in use Cargo Cover Cleaning If the cargo cover has deteriorated replace it The cargo cover is a waterproof welded plastic coated polyester Wash the cover using only mild soap and water Do not use cleaning agents that are petroleum based or that contain acid or abrasives All cleaning agents should be flushed promptly and not allowed to dry on the surface Do not towel dry or wax the surface The windows shoul
72. Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Blackout B O Lamp Wiring Harness Front Removal Procedure Caution Refer to Battery Disconnect Caution in Caution and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2 Disconnect the blackout B O headlamp connectors 1 from the blackout B O headlamp 3 Disconnect the blackout B O marker lamp connectors 2 from the blackout B O marker lamp 4 Trace the blackout B O lamp harness connector 3 to the main harness connector 5 Disconnect the blackout B O lamp harness connector 3 to the main harness connector 6 Remove the wiring harness from the vehicle Note wiring harness routing for installation Installation Procedure 1 Position the blackout B O lamp wiring harness onto the vehicle in the same routing location as removed 2 Connect the blackout lamp harness connector 3 to the main harness connector 3 Connect the blackout B O marker lamp connectors 2 to the blackout B O marker lamps 4 Connect the blackout B O headlamp connectors 1 to the blackout B O headlamp 5 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2004 LSSV Truck 8 54 Wiring Systems Body and Accessories Winch Connector Harness Replacement Front Removal Procedure Caution
73. Inoperative Utility 6 23 Voltmeter Lamp Inoperative 6 22 Repair 24V Converter Fuse Replacement 6 41 24V Generator Replacement 6 36 24 Voltmeter Relay Replacement Ultility 6 40 Battery Cable Disconnect Connect c etie ecce 6 37 Battery Tray Battery Replacement 6 34 Circuit Breaker Bracket Replacement 6 33 Circuit Breaker Replacement 12V or 24V 6 32 Jump Starting in Case of Emergency 6 31 Power Converter Replacement Utility 6 41 Relay Replacement 24V 6 34 Vehicle Load Disconnect Switch 6 38 5 6 3 Specifications Fastener Tightening Specifications 6 3 Exterior and Interior Colors 8 177 Exterior Painting Repair Exterior Painting 1 8 178 Exterior Trim Description 2004 LSSV Truck Index Exterior rte 8 132 Repair Radiator Grille 8 130 Rear Mud Flap Replacement 8 130 Spiecifications Fastener Tightening Specifications 8 129 F Fibreglass Top Replacement 8 168 Floor Mat Repair Floor Mat Replacement
74. Install the data plate 1 to the original holes 2 Install the new rivets 3 Floor Mat Replacement Removal Procedure 1 Remove bolts securing gun rack 1 and remove mount Refer to Gun Rack Replacement Lower or Gun Rack Replacement Floor Mount Crew Cab or Gun Rack Replacement Floor Mount Utility 2 Remove floor mat Refer to Carpet Replacement Front W O HP2 in Interior Trim in the 2004 C K Truck Service Manual 2004 LSSV Truck 8 162 Interior Trim Body and Accessories Installation Procedure 1 Using the old floor mat as a template cut gun rack holes in the new floor mat 2 Install the floor mat Refer to Carpet Replacement Front W O HP2 in Interior Trim in the 2004 C K Truck Service Manual 3 Install gun rack 1 and install bolts Refer to Gun Rack Replacement Lower or Gun Rack Replacement Floor Mount Crew Cab or Gun Rack Replacement Floor Mount Utility Gun Rack Replacement Floor Mount Crew Cab Removal Procedure 1 Remove the rear bolts securing gun rack to the floor 2 Loosen the inner rear front seat bolts enough to slide back 3 Remove the gun rack 1 from vehicle 2004 LSSV Truck Interior Trim 8 163 Body and Accessories Installation Procedure 1 Install the gun rack 1 and slide under the front seat bolts 2 Align the rear transfer holes with holes in the floor Notice Refer to Fastener Notice in Cautions and Notices
75. LK Information SHD BLK Wire Circuit 2 Wire Circuit Color No Function Pin Color No Function A BRN 2109 Park Lamps A BRN 2109 Park Lamps B YEL 1618 S T Lamps Left B YEL 1608 S T Lamps Left BLK 1750 Ground BLK 1750 Ground D DK GRN 1619 S T Lamps Right D DK GRN 1619 S T Lamps Right 2004 LSSV Truck ody and Accessories Inline Harness Connector C907M Wiring Systems 8 4 DOQQ DOQQ c etc JEAN 10583 10584 e 12020832 e 12020830 Connector Part Connector Part e 4 Way F Weather Pack e 4 Way M Weather Pack Information TWR BLK Information SHD BLK Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function A BRN 2109 Park Lamps A BRN 2109 Park Lamps B YEL 1618 S T Lamps Left B YEL 1618 S T Lamps Left BLK 1750 Ground BLK 1750 Ground D DK GRN 1619 S T Lamps Right D DK GRN 1619 S T Lamps Right Inline Harness Connector C908M 2999 rss Num C D D C B A 10583 10584 e 12020832 e 12020830 Connector Part Connector Part 4 Way F Weather Pack 4 Way M Weather Pack Information TWR BLK Information SHD BLK Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function A BRN 2109 Trailer Park Lamp A BRN 2109 Trailer Lamp Supply Supply Voltage Voltage B YEL 1608 Left Stop Turn Supply YEL 1608 Left Stop Turn Supply Voltage Vol
76. Mode Blackout Lamp Wiring Harness Front Blackout B O Lighting Blackout Headlamp Always Blackout Headlamp Inoperative Headlamps Operate in Blackout B O Mode Description Blackout B O Lighting Circuit Operation Repair Blackout Switch Replacement Blackout B O Marker Lamps Diagnosis Blackout Marker Lamps Inoperative Blackout Marker Lamps Diagnosis Blackout B O Marker Lamps Always On Body Rear End Description Body Rear End Repair Cargo Cover Front End Rail Replacement Cargo Cover Rear End Rail Replacement Cargo Cover Replacement Cargo Cover Side Rail and Hinge ereenn Cargo Cover Stowage Replacement Cargo Cover Strut Replacement Cargo Cover Top Bows Replacement Fiberglass Top Replacement Maintenance Body Replacement Specifications Fastener Tightening Specifications Bumpers Description BUMPO ete de ette den it Winch Repair Bumper Reinforcement Rear Bumper Replacement Front Bumper Replacement Front Utility Bumper Replacement Rear Maintenance Body iei
77. Procedure Important Use a standard 194 bulb for replacement 1 Install the license plate lamp 2 into the opening of the bumper 2 Hold the lamp and slide the retainer 1 onto the back of the lamp 2 3 Install the bulb socket 2 and bulb to the back of the lamp 2004 LSSV Truck Lighting Systems 8 111 Body and Accessories License Plate Lamp Replacement Utility Removal Procedure 1 Ensure that the headlamp switch is in the OFF position 2 Remove the screw 1 in the center of the license plate lamp and remove the lens cover 2 from the bracket 3 Remove the bulb from the socket SAY NANNY Y RAY UN SN RS NN Installation Procedure Important Use a standard 194 bulb for replacement 1 Install the bulb into the socket 2 Install the lens cover 2 onto the license plate bracket and install the screw 1 SS SN X SY NS Iw SS D NO SSY ES License Plate Bracket Replacement Utility Removal Procedure 1 Remove the license plate from the bracket 2 Disconnect the electrical connector from the bracket 3 Remove the bolts 1 and nuts from the bracket 4 Remove the bracket 2 from the bumper 2004 LSSV Truck 8 112 Lighting Systems Body and Accessories WESABE s NN NON WSS Y A 4 AKO L 2004 LSSV Truck Installation Procedure Install the bracket 2 onto bumper and align the holes Install the bolt
78. Receiver Pickup The hitch receiver for the pickups is integral to the front and rear bumper assemblies The receiver will allow use of different components such as a pintle hook or multi mount winch Hitch Receiver Maintenance Body The rear hitch receiver on the maintenance body is mounted below the rear bumper to the clevis tie down plates The receiver will allow use of different components such as a pintle hook or multi mount winch 2004 LSSV Truck 8 184 Frame and Underbody Body and Accessories BLANK 2004 LSSV Truck Index A Accessory Panel Replacement Auxiliary Lamp Extension Harness Replacement Auxiliary Lamp Harness Replacement Front Axle Description Front Axle Vent Tube Filter Description Rear Axle Vent Tube Filter Description Repair Front Axle Vent Tube Filter Replacement Rear Axle Vent Tube Filter Replacement Backup Lamps Diagnosis Backup Lamps Inoperative Backup Lamps Operate in Blackout B O iso Battery Description Battery Description 12V and 24V Repair Battery Cable Disconnect Connect aee RR ees Battery Tray Battery Replacement Blackout B O and Trailer Harness Replacement Blackout Horns Horns Operate in Blackout
79. SERVICE MANUAL 2004 Light Service Support Venicle LSSV Includes General Information Military Components ety SI VOLUME 1 OF 1 LSSVSMO04 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 careful
80. Tie Down Replacement Front 3 Remove the Front Bumper Refer to Bumper Replacement Front Utility 4 Remove the bracket 3 by removing the bolts 2 5 Remove the side mounting bolt 1 washer and nut 5 6 Remove the front clevis tie down support 4 Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 1 Install the front clevis tie down support 4 with side mounting bolt 1 washer and nut 5 Tighten Tighten side mounting bolts to 80 95 N m 59 70 Ib ft 2 Install the bracket 3 with bolts 2 and tighten Tighten Tighten bracket bolts to 80 95 N m 59 70 Ib ft 3 Install the front bumper Refer to Bumper Replacement Front Utility 4 Install the front clevis tie downs Refer to Clevis Tie Down Replacement Front 5 Install the engine shield if equipped Body and Accessories Bumpers 8 143 Bumper Replacement Rear Pickup Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Remove the negative battery cable of the right battery and the 12V and 24V cables of the left battery 2 Remove the pintle hook Refer to Pintle Hook Replacement 3 Disconnect the trailer wiring harness Refer to Blackout B O and Trailer Harness Replacement Rear in Wiring Systems 4 Remove the winch connector Refer to Winch Connector Harness Replacement Rear in Wiring Systems 5 Support the rear bumper using an approved sup
81. Voltmeter Replacement 8 119 Accessory Panel Replacement 8 119 Blackout Switch Replacement 8 121 Description and Operation 8 122 Instrument Panel and Gages Description 8 122 amp fe 8 123 Schematic and Routing Diagrams 8 123 Diagnostic Information and Procedures 8 125 Symptom LUS sss eee eee eee 8 125 Description and Operation 8 127 Horn with Blackout B O Control Circuit Operation 8 127 Exterior Trim eost idest iesus 8 129 Specifications eere 8 129 Repair Instructions eee 8 130 Rear Mud Flap Replacement 8 130 Radiator Grille Replacement 8 130 Description and Operation 8 132 Exterior Trim Description 8 132 1 ibn nodo iode 8 133 Specifications eese 8 133 Repair Instructions eese 8 134 Bumper Replacement Front 8 134 Bumper Replacement Front Utility 8 137 Slave Receptacle Replacement 8 138 Radiator Grille Brush Guard Replacement AUi 8 140 Clevis Tie Down Replacement Front 8 141 Clevis Tie Down Repl
82. Winch Connector Harness Replacement cere 8 54 Winch Connector Harness Replacement cre etry 8 56 Wiring Components Electrical Center Identification Views 8 28 Inline Harness Connector End Views 8 29 Master Electrical Component List 8 12 Power and Grounding Component Views 8 17 Description Wiring 8 59 Repair 12V and 24V Harness Replacement 8 52 Auxiliary Lamp Harness Replacement mio ge aie alata 8 45 Auxiliary Lamp Extension Harness Replacement 8 46 Blackout B O and Trailer Harness Replacement 8 52 Blackout B O Lamp Wiring Harness docte 8 53 Commercial Trailer Connector Replacement esee 8 48 Lamp Harness Replacement Rear 8 47 Military Trailer Connector Replacement 8 50 Military Trailer Connector Replacement Factory 8 49 Relay Mounting Bracket Replacement 8 50 Slave Receptacle Harness Replacement 8 57 Winch Connector Harness Replacement EOD iiri ot ete sert a LER ERI TUAE 8 54 Winch Connector Harness Replacement EE 8 56 Repair 5 r
83. acement Front TERRE 8 141 2004 LSSV Truck 8 2 Table of Contents Body and Accessories Clevis Tie Down Support Replacement Front Utility seen 8 142 Bumper Replacement Rear Pickup 8 143 Bumper Reinforcement Rear 8 144 Bumper Replacement Rear Utility 8 145 Pintle Hook Replacement 8 148 Clevis Tie Down Replacement Rear Military BUMpPeP 8 149 Clevis Tie Down Bracket Replacement Rear wane eae eto ets 8 149 Clevis Tie Down Replacement Rear ii ioo tt eter Reed 8 150 Bumper Replacement Rear Maintenance Aat ntes ta 8 151 Tie Down Plate Replacement Rear Maintenance 8 152 Reinforcement Bar Replacement Maintenance 8 153 Description and Operation 8 154 ST sa metr 8 154 Winch Recevet sese ee eee eee 8 154 SOAS M 8 155 Specifications sss cesse 8 155 Repair Instructions eese 8 157 Seat Replacement 8 157 Description and Operation 8 158 Folding Rear 8 158 Interior TEHTI sire ruso ip kii
84. acement 8 48 Military Trailer Connector Replacement Factory 8 49 Military Trailer Connector Replacement 8 50 Relay Mounting Bracket Replacement 8 50 Blackout B O and Trailer Harness Replacement 8 52 12V and 24V Harness Replacement 8 52 Blackout B O Lamp Wiring Harness cet had et 8 53 Winch Connector Harness Replacement ELO 8 54 Winch Connector Harness Replacement HOO aae a 8 56 Slave Receptacle Harness Replacemert 8 57 Description and Operation 8 59 Wiring Description sees eee eee ee eee ee 8 59 Lighting Systems 8 61 Specifications 8 61 Schematic and Routing Diagrams 8 61 Component 8 71 Lighting Systems Component Views 8 71 Lighting Systems Connector End Views 8 83 Diagnostic Information and Procedures 8 86 Symptom List e nee 8 86 Repair Instructions eee 8 99 Headlamp Replacement Blackout B O PICKUp Loco repite inte ens 8 99 Headlamp Replacement Blackout B O muc EE 8
85. ached to a hose with a vented cap at the end and is mounted under the vehicle next to the left side of the transfer case The filter must be inspected occasionally to see if it needs to be replaced Refer to Periodic Maintenance Inspection in Maintenance and Lubrication 2004 LSSV Truck Engine Table of Contents 6 1 Section 6 Engine Engine 6 3 Repair Instructions 6 31 Specifications iir cre 6 3 Jump Starting in Case of Emergency 6 31 Schematic and Routing Diagrams 6 3 Circuit Breaker Replacement 12V or 24 6 32 Component Locator 6 11 Circuit Breaker Bracket Replacement 6 33 Starting and Charging Component Views 6 11 Battery Tray Battery Replacement 6 34 Starting and Charging Connector End Relay Replacement 24V Generator 6 34 6 20 24V Generator Replacement 6 36 Diagnostic Information and Procedures 6 22 Battery Cable Disconnect Connect SVITIDIONI EISE cina vertit ced 6 22 Proced te x eet E RR 6 37 Voltmeter Lamp Inoperative 6 22 Vehicle Load Disconnect Switch Voltmeter Inoperative Utility DOREM EN 6 23 Replacement URINE REDE SONT NODE TU 6 38 Voltmeter Inaccurate or Inop
86. ackout B O Stoplamps B O Stoplamps B BRN WHT 900 Left Rear Blackout B BRN WHT 900 Left Rear Blackout B O Marker Lamps B O Marker Lamps Inline Harness Connector C904M 14635 14634 Connector Part 12952831 Connector Part 12162000 Information e 2 Way F MP 150 Series Information 2 Way M MP 150 Series Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function A BLK 1050 CHML Supply A RED 1620 CHML Supply Voltage Voltage B BLU 1050 Ground B BLK 1050 Ground 2004 LSSV Truck 8 40 Wiring Systems Body and Accessories Inline Harness Connector C905M AS 9999 AER eS m A C D 10583 10584 e 12020832 e 12020830 Connector Part Connector Part e 4 Way F Weather Pack e 4 Way M Weather Pack Information TWR BLK Information SHD BLK Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function A BRN 915 Park Lamps A BRN 9 Park Lamps B YEL 18 S T Lamps Left B YEL 18 S T Lamps Left BLK 19 Ground BLK 150 Ground D GRN 916 S T Lamps Right D DK GRN 19 S T Lamps Right Inline Harness Connector C906M 2999 rss A D D C B A 10583 10584 e 12020832 e 12020830 Connector Part Connector Part e 4 Way F Weather Pack e 4 Way M Weather Pack Information TWR B
87. and Notices 1 2 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Remove the accessory panel Refer to Accessory Panel Replacement in Instrument Panel Gages and Console Remove the voltmeter lamp socket from the back of the voltmeter Remove the bulb 1 from the voltmeter socket Installation Procedure Important Use a standard 194 bulb for replacement 1 2 3 Install the bulb 1 into the voltmeter socket Install the lamp socket into the voltmeter Install the accessory panel Refer to Accessory Panel Replacement in Instrument Panel Gages and Console Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Taillamp Replacement Maintenance Body Removal Procedure PO mot Ensure that the headlamp switch is in the OFF position Remove the nuts 2 from the rear bumper 1 Remove the lamp from the rear bumper Disconnect the lamp from the wiring harness Lighting Systems 8 10 2004 LSSV Truck 7 8 108 Lighting Systems Body and Accessories 2004 LSSV Truck 15683 15683 Installation Procedure 1 Install the wiring harness to the lamp Notice Refer to Fastener Notice in Caution and Notices 2 Install the lamp onto the rear bumper 1 and install nuts 2 Tighten Tighten the nuts to 27 N m 20 Ib ft Taillamp Bulb Replacement Maintenance Body Removal Procedure
88. between 7V the generator terminal B and ground Is the voltage greater than the specified voltage Using a DMM measure the voltage from the BATT 4 terminal and ground 7V Is the voltage greater than the specified voltage Go to Step 5 Go to Step 7 FS Does the test lamp illuminate 2004 LSSV Truck Engine Engine Electrical 6 27 24V Generator Inoperative Pickup cont d Repair the generator voltage circuit for an open or high resistance Go to Step 17 Go to Step 17 Go to Step 10 Go to Step 12 Goto Step 14 Did you complete the repair Test the generator ground circuit for an open or high resistance Did you find and correct the condition Repair the generator field circuit for an open or high resistance Did you complete the repair Replace the generator Refer to 24V Generator Replacement Did you complete the replacement Connect a test lamp between terminal 85 and ground Did the test lamp illuminate Repair the 24V relay control voltage circuit for an 3 open or high resistance Did you complete the repair Connect a test lamp between terminal 87 of the 24V 4 relay and ground Go to Step 15 Goto Step 13 Go to Step 17 System OK Go to Step 2 For testing the dual batteries or 24V battery use Out of Vehicle test for each battery Refer to Battery Inspection Test in Engine Electrical in 2004 C K Truck Service Manual Did the test lamp illuminate Replace
89. cap to the assembly 2 Remove the lens cap 2 and O ring 3 Remove the bulb from the lamp socket Installation Procedure Important Use a standard 1073 bulb for replacement 1 Install the new bulb in the lamp socket Notice The O ring installation must be a proper fit 2 Install the O ring with the lens cover 2 3 Install the 3 screws 1 to the assembly Body and Accessories Lighting Systems 8 101 Marker Lamp Replacement Front Blackout B O Pickup Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2 Remove the wiring harness strap 4 from the marker lamp harness 3 Remove the harness connector 3 by releasing the connector tab 4 Remove the nuts 1 and the ground connector 2 from the marker lamp 5 Remove the blackout B O marker lamp assembly 1 from the bumper Installation Procedure 1 Install the marker lamp 1 into the front bumper opening 2004 LSSV Truck 8 102 Lighting Systems Body and Accessories 2004 LSSV Truck 10344 Notice Refer to Fastener Notice in Cautions and Notices 2 Install the nuts 1 and the ground connector 2 onto the maker lamp studs Tighten Tighten marker lamp nuts to 2 Nem 18 lb in Install the harness connector 3 to the marker lamp connector Secure the harness in the original
90. cement Remove the nuts 4 from the back of the voltmeter Remove the voltmeter bracket 3 and remove the voltmeter 1 from the panel Installation Procedure 1 2 Install the voltmeter 1 into the panel opening Install the bracket 3 on the back of the voltmeter Notice Refer to Fastener Notice in Cautions and Notices 3 4 5 Install the nuts 4 on the voltmeter studs Tighten Tighten nuts to 2 8 Nem 24 lb in Install the accessory panel Refer to Accessory Panel Replacement Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Accessory Panel Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 2 3 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Remove the fasteners 1 from the panel Move the panel 2 out far enough to gain access to the harness connections 2004 LSSV Truck 8 120 Instrument Panel Gages and Console Body and Accessories 2004 LSSV Truck PRR 1 C D HN He gt Disconnect the 24V meter bulb and harness connectors 1 from the meter Disconnect the blackout B O harness connectors 2 from the switches Remove the panel 3 from the vehicle Remove the parts from the accessory panel Refer to Voltmeter Replacement or Blackout B O Switch Replacement Insta
91. ct Connect Procedure Engine Engine Electrical 6 41 Power Converter Replacement Utility Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure 2 Remove bolts 1 securing converter to the bracket 3 Lift converter 2 out of bracket enough to gain access to the wiring connections 4 Remove the wiring from the connectors Note removal position of wiring for installation Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 1 Install wiring to the converter connection in the same position as removed and tighten Tighten Tighten converter connections to 12 N m 110 Ib in 2 Install converter 2 in bracket and tighten bolts 1 Tighten Tighten converter bolts to 6 10 N m 53 89 Ib in Important Verify that the wiring is not pinched and that the converter terminals are not touching the metal bracket 3 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure 24V Converter Fuse Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure 2 Remove the nuts wires and fuse hardware from the fuse link studs Leave nylon shoulder washers 1 on the studs Note removal of wiring for installation 3 Clean stud threa
92. d Installation Procedure 1 2 Install the 2 plastic bushings 1 to the inside and 1 to the outside of the base hole of each side strut Install the front strut 857 25 mm 33 75 in inside the base of the hinge bracket at the first hole Use a nylock nut on the inboard side and a bolt on the outboard side of the bracket Install the center strut 571 50 mm 22 5 in inside the bracket at the mid level hole with a nylock and bolt in similar fashion Notice Refer to Fastener Notice in Cautions and Notices 4 Install the rear strut 821 43 mm 32 34 in at the top hole with the nylock and bolt in similar fashion Tighten Tighten the strut bolt to 5 Nem 44 Ib in Install the cargo cover and top bows Refer to Cargo Cover Replacement and Cargo Cover Top Bows Replacement Cargo Cover Top Bows Replacement Removal Procedure Remove the cargo cover Refer to Cargo Cover Replacement Remove the strap tensioners from the front and rear top bows by withdrawing from the side rail loop Remove the 6 pins 1 holding the 3 top bows to the 6 side struts Remove the 3 top bows from the struts Slide the strap off each top bow Remove the bows from the vehicle Body and Accessories Installation Procedure 1 Slide the strap onto the top bows at the center 2 Attach the retainer pin 1 assembly as shown at the base of each bow end Notice Refer to Fastener Notice in Cautions and Notices 3 Attach the retain
93. d be washed with a water soaked cloth Do not rub dry 2004 LSSV Truck Fiberglass Top The fiberglass top is a hard top cover supported by the bed rails and has side and back windows that are able to open and lock Refer to the 2004 Owner s Manual Military Supplement for further details Maintenance Body The maintenance body is mounted to the pickup chassis using the same attachment locations as a pickup bed The maintenance body has multiple lighted locking doors and an open cargo space Body and Accessories Paint Coatings 8 177 Paint Coatings Paint Codes Exterior and Interior Colors Location Color Fed std 595 B PPG No Forest Green 34094 CA 8211 15086 Desert Tan 8 8211 107036MPY228 For specific paint coating details contact PPG Automotive Coatings at 1 818 549 7979 2004 LSSV Truck 8 178 Paint Coatings Body and Accessories Repair Instructions Exterior Painting Metal Refinishing 1 Remove all exterior ornaments and emblems from the panel to be painted 2 Prepare all metal surfaces to be painted Note Cut paint at door seals remove or mask over door seals 3 Repaint all exterior metal with lustreless paint Refer to Exterior and Interior Colors Chart for current paint part number Important This is not CARC Chemical Agent Resistant Coating paint The recommended supplier is PPG 4 Remove masking tape Notice Exercise care when removing masking and handling vehicle afte
94. d you complete the replacement Go to Step 24 Connect a test lamp between the output stud of the 12V circuit 7 breaker and ground Does the test lamp illuminate Go to Step 8 Go to Step 10 P Locate and repair the open or high resistance in circuit 152 Did you complete the repair Go to Step 24 pes B Connect a test lamp between the longer 24V stud and ground Does the test lamp illuminate Go to Step 14 Go to Step 15 Connect a test lamp between the input stud of the 12V circuit 10 breaker and ground Does the test lamp illuminate Go to Step 12 Go to Step 13 Connect a test lamp between the IGN stud of the converter and 11 ground Does the test lamp illuminate Go to Step 16 Go to Step 19 Inspect for the following conditions e High resistance or short to ground on circuit 152 ka e Faulty or weak 12V circuit breaker Did you find and correct the condition Go to Step 24 T Locate and repair the open or high resistance in circuit 900 Did you complete the repair Go to Step 24 m 2004 LSSV Truck Engine Engine Electrical 6 29 Power Converter Inoperative Utility cont d Step Action Yes No 1 Locate and repair the source of the overload 2 Replace the converter fuse Refer to 24V Converter M Fuse Replacement Did you complete the repair Go to Step 24 Connect a test lamp between the 24V circuit breaker output 15 stud and ground Does the test lamp illuminate Go to Step 20 Go to Step 17 Connect a test la
95. ds with steel wool or a wire brush Clean the contact surface of the inside jam nuts 5 4 Disconnect fuse link 6 and discard 2004 LSSV Truck 6 42 Engine Electrical Engine Installation Procedure 1 Install the flat washers 4 over the nylon shoulder washers 1 2 Install the inside jam nuts 5 as follows with a wrench tighten and loosen each nut a few times to clean the threads From a finger tight position loosen the jam nuts about a turn Notice Refer to Fastener Notice in Cautions and Notices Note Do not tighten the inside jam nuts 3 Install the fuse link 6 fuse cover 7 flat washers 8 and the fuse retaining nuts 9 and 10 full height nut 9 on long stud 2 and jam nut 10 on short stud 3 Tighten Tighten fuse retaining nuts to 12 Nem 110 Ib in 4 Install the wiring 11 in the same location as removed 5 Install the lock washer 12 and the full height nut 13 on the long stud 2 and tighten Tighten Tighten nut to 12 N m 110 Ib in 6 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure 2004 LSSV Truck Engine Engine Electrical 6 43 Description and Operation Battery Description 12V and 24V The engine electrical options include the slave receptacle battery equalizer or 24V generator and a two or three battery power system The two batteries in series provide 24V of power which is isolated by the power equalizer and controlled by
96. e new cover will be a tighter fit 1 Install the cargo cover to the top bows and align so that the velcro strips are at the corners 2 Install or attach all interior retainers to the bows struts and loops 3 Press the velcro flaps down 4 Install the cover to the front end and side in hooks and pull strap at the base of the cover as needed Cargo Cover Stowage Replacement 1 Release the front and rear support straps 2 From the rear of the vehicle push the bows and canvas forward folding the canvas around the bows Note The cover may also be folded neatly and stored behind the seat in the cab 3 Completely fold the bows down against the front of the cargo box and secure them with the front straps Maintenance Body Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Caution and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2 Disconnect the wiring harness for the maintenance body 3 Remove the rear bumper assembly Refer to Bumper Replacement Rear Maintenance Body in Bumpers 4 Disconnect fuel fill and vent hoses from fuel fill bucket 5 Remove the maintenance body fasteners from the frame rails 6 Lift and remove the maintenance body 1 from the chassis Body and Accessories Body Rear End 8 175 Installation Procedure 1 Align the maintenance body 1 on the frame rails Notice Refer to Fastener Notice in
97. e noise decreased or stopped System OK Go to Step 10 Compare the vehicle with a known good vehicle Do both vehicles make the same noise System OK Go to Step 10 Important If no definite generator problems were found be sure that all other possible sources of objectionable noise are eliminated before replacing the generator Replacing the generator may not change the noise level if the noise is a normal characteristic of the generator or the generator mounting Replace the generator Refer to 24V Generator Replacement Has the noise decreased or stopped Go to Step 11 s Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 24V Generator Inoperative Pickup 24V Generator Inoperative Pickup km Ye Schematic Reference Engine Electrical Did you review the Charging System Description and Go to Operation Description Go to Step 2 and Operation Using a DMM measure the voltage across the 24V battery terminals 18 0 28 5V Go to Battery Inspection Is the voltage between the specified voltage Go to Step 3 Test 24V Go to Step 4 Go to Step 6 Connect a test lamp between ground terminal of the generator and battery negative Does the test lamp illuminate Go to Step 8 Go to Step 10 Go to Step 9 Go to Step 11 Connect a test lamp between terminal 30 of the 24V relay and ground 1 Start the engine 3 2 Using DMM measure the voltage
98. e rear axle is specially equipped with a vent tube filter to protect the axle from contaminants found in the off road environment It is attached to a hose with a vented cap at the end The rear axle vent filter is mounted near the top of the axle housing and the hose is attached to the brake bracket on the driver s side frame rail The filter must be inspected occasionally to see if it needs to be replaced Refer to Periodic Maintenance Inspection in Maintenance and Lubrication 2004 LSSV Truck 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 Caution Refer to Vehicle Lifting Caution in Cautions and Notices 1 Raise and support the vehicle 2 Install safety stands 3 Remove the filter 1 from the hose and discard Installation Procedure Notice The filter arrow must point toward the transfer case If replacing the hose the length of the new hose must match the length of the old hose 1 Install the filter 1 to the hoses 2 Remove safety stands 3 Lower the vehicle CY 2004 LSSV Truck 4 8 Transfer Case Driveline Axle Description and Operation Transfer Case Vent Tube Filter Description The transfer case is specially equipped with a vent tube filter to protect the transfer case from contaminants found in the off road environment The vent filter is att
99. e rear bumper 1 loosely to the frame rail with the bolts and the washers and nuts Install the rear bumper loosely to the brace s at the upper attaching points with the bolts and nuts Install the rear bumper loosely to the brace s at the lower attaching points with the bolts and nuts Body and Accessories Bumpers 8 147 4 Connect the trailer lamp connectors 2 3 5 Connect the blackout B O marker lamp connector 2 and the ground lead to 1 to the mounting bracket SS 5 SE L LS pm RZ Skt Tl 9255 Z 2 Notice Refer to Fastener Notice in Cautions and Notices 6 Finish installing all attaching hardware Install the bolts Tighten Tighten the frame bolts to 90 Nem 66 lb ft Tighten the brace bolts to 90 Nem 66 lb ft 7 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 8 Install the lower step pad 2004 LSSV Truck 8 148 Bumpers Body and Accessories 9 Install the pintle hook into the receiver Pintle Hook Replacement Removal Procedure Note Pickup shown all others similar 1 Remove the spring clip 2 from the retaining pin 2 Remove the retaining pin 1 from the receiver 3 Pull the pintle hook 3 out of the receiver Installation Procedure 1 Clean any debris out of the receiver Push pintle hook 3 into receiver until holes line up Install retaining pin 1 into h
100. e rear lamp harness connector from the rear lamp extension harness Remove the 2 rear lamp harness connectors 7 8 from the trailer jumper Installation Procedure 1 2 Install the rear lamp harness connector to the taillamp connectors Install the ground lead nut ground lead and connector to the blackout B O marker lamp Install the two rear lamp harness connectors 7 8 to the trailer jumper Install the rear lamp harness connector to the auxiliary rear lamp extension harness Install the vehicle ground lead bolt washer and harness ground Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2004 LSSV Truck 8 48 Wiring Systems Body and Accessories Commercial Trailer Connector Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2 Disconnect the harness connector 4 from the trailer connectors 1 3 Release the lock table turn the trailer connector 1 and pull out from the bumper Installation Procedure 1 Install the trailer connector 1 into the opening in bumper 2 Turn the connector until lock tabs engage 2004 LSSV Truck Body and Accessories Wiring Systems 8 49 3 Connect the harness connector 4 into the trailer lamp connector 1 4 Connect the battery cables
101. eci iter eae la cae 8 3 Specifications Fastener Tightening Specifications 8 3 2004 LSSV Truck SERVICE MANUAL 2004 Light Service Support Vehicle LSSV
102. eee neris Bumper Replacement Rear Pickup Bumper Replacement Rear Utility Clevis Tie Down Bracket Replacement Rear UUI orgnr eisereen Clevis Tie Down Replacement Front Clevis Tie Down Replacement Rear UHV enero PR tnis Clevis Tie Down Replacement Front Utility 4 3 ctn on nes Clevis Tie Down Replacement Rear Military Bumper sexe eee ee Clevis Tie Down Support Replacement Front Pintle Hook Replacement Radiator Grille Brush Guard Replacement Radiator Grille Brush Guard Replacement Utility i Lai tete biens Reinforcement Bar Replacement Maintenance Body Slave Receptacle Replacement Tie Down Plate Replacement Rear Maintenance Specifications Fastener Tightening Specifications Cargo Cover Repair Cargo Cover Front End Rail Replacement Cargo Cover Rear End Rail Replacement Cargo Cover Replacement Cargo Cover Side Rail and Hinge Cargo Cover Stowage Replacement Cargo Cover Strut Replacement Cargo Cover Top Bows Replacement Charging System Description Charging System Description and T Circuit Breaker Repair Circuit Breaker
103. efer to Battery Cable Disconnect Connect Procedure in Engine Electrical Marker Lamp Replacement Rear Utility Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2 Remove the nut 1 from the bracket and remove the marker lamp assembly 2004 LSSV Truck 8 106 Lighting Systems Body and Accessories 2004 LSSV Truck Disconnect the harness connector 2 by releasing the connector tab Remove the nut holding the ground lead 1 and the nut to the stud Remove the opposite nut holding the bracket to the other stud Remove the blackout B O marker lamp assembly 3 from the bracket Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 1 Install the marker lamp 3 to the bracket with nuts and tighten Tighten Tighten the nuts to 2 Nem 18 Ib in Install the ground lead to the stud with a nut and tighten Tighten Tighten the nut to 2 Nem 18 Ib in Connect the harness connector 2 to the lamp connector Install the marker lamp assembly into the opening in the bumper and tighten nut 1 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Body and Accessories Lamp Replacement Voltmeter Removal Procedure Caution Refer to Battery Disconnect Caution in Caution
104. er Case Unit Repair Manual TURM available separately The TURM contains information on automatic and manual transmissions and transaxles including the fluid flow and circuit description information Technicians who understand the material in this manual and in the appropriate Dealer Service Bulletins better serve 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 1000 2004 GENERAL MOTORS CORPORATION ALL RIGHTS RESERVED The information cutoff date is 01 20 2005 LITHO IN U S A PART NO LSSVSM04 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 BLANK Table of Contents Table of Contents 1 Table of Contents Preface Body and Accessories Wiring 8 3
105. er cover strap assembly 2 to the holes on both the left and right sides of the center top bow as shown Attach the straps to the inboard sides of each with a nut Tighten Tighten the 2 cover strap retaining nuts to 5 Nem 44 Ib in 4 Slide the front roof bow onto the front struts and install the pins into the bow strut holes 5 Slide the center roof bow on the center struts and install the pins into the bow strut holes 6 Slide the rear roof bow onto the rear struts and install the pins into the bow strut holes 7 Install the strap tensioners to the front and rear top bows by threading them through the retainer loop of the side rail Note The buckle should face inboard 8 Install the cargo cover Refer to Cargo Cover Replacement Cargo Cover Replacement Removal Procedure 1 Pull apart the velcro corners of the front and rear flaps and roll the cargo cover up over the top 2 Remove the cargo cover from the side rail and end gate retainers by releasing tension and removing hook Pull cover free 3 Untie release or unbuckle all cover retainers 4 Remove the cargo cover Body Rear End 8 17 2004 LSSV Truck 3 8 174 Body Rear End Body and Accessories 2004 LSSV Truck Installation Procedure Important All trailing edges must fall to the proper length at each side of the box rail All tether ties must appear on the interior Provide adequate slack between the bow straps and the cover Th
106. er to verify the repair Did you correct the condition System OK Go to Step 2 Blackout B O Marker Lamps Always On Step Action Yes No Schematic Reference Lighting Systems Schematics 1 Did you review Blackout B O Lighting Description and Go to Description Operation Go to Step 2 and Operation Verify that the marker lamps are always on Go to Testing for Do the marker lam rate normally 160068 2 ae alise pS operaie Intermittents in Wiring Systems of the 2004 C K Truck Service Manual Go to Step 3 2004 LSSV Truck Body and Accessories Lighting Systems 8 93 Blackout B O Marker Lamps Always On cont d Step Action Yes No 1 Disconnect the blackout B O service switch 3 2 Connect a test lamp between circuit 911 PNK cavity A wire and ground Does the test lamp illuminate Go to Step 4 Go to Step 5 Repair a short to power in circuit 911 PNK or circuit 900 BRN WHT wire s between the blackout B O service 4 switch and blackout B O marker lamps Did you complete the repair Go to Step 6 Replace the blackout B O service switch j Did you complete the replacement Go to Step 6 m Operate the system in order to verify the repair j Did you correct the condition System OK Go to Step 2 DRL Operate in Blackout B O Mode Step Action Yes No Schematic Reference Lighting Systems Schematics 1 Did you review Blackout B O Lighting Description and Go to Desc
107. erative 24 Voltmeter Relay Replacement Utility MEENT 6 40 Pickup 6 24 Power Converter Replacement Utility 6 41 24V Generator Noise Diagnosis 6 25 24V Converter Fuse Replacement 6 41 24V Generator Inoperative Pickup 6 26 Description and Operation 6 43 Battery Inspection Test 24V 6 27 Battery Description 12V and 24V 6 43 Power Converter Inoperative Utility 6 28 Charging System Description and Circuit Power Converter 6 30 Operation KE TEI IPIE L EO E 6 43 2004 LSSV Truck 6 2 Table of Contents Engine BLANK 2004 LSSV Truck Engine Engine Electrical 6 3 Engine Electrical Specifications Fastener Tightening Specifications Specification Application Metric English Battery Cable Connections 17 13 Ib ft Battery Retainer Bolt 25 Nem 18 Ib ft Circuit Breaker Bracket Bolts 6 Nem 53 Ib in Converter Connections 12 N m 110 Ib in Converter Fuse Nuts 12 N m 110 Ib in Converter Mounting Bolts 6 10 N m 53 89 Ib in Generator Mounting Bolts 50 Nem 37 Ib ft Generator Output Stud Nut 9 N m 80 Ib in Vehicle Load Disconnect Switch Nuts 9 80 Ib in Schematic and Routing Diagrams 2004 LSSV Truck Engine 6 4 Engine Electrical
108. ervice switch connector from the switch 3 2 Connect a test lamp at cavity C of the connector and ground Does the test lamp illuminate Go to Step 5 Go to Step 4 7 Replace the blackout B O service switch Did you complete the replacement Go to Step 9 mE Locate and repair the short to voltage on circuit 912 ORN 3 Did you complete the repair Go to Step 9 Eu 2004 LSSV Truck 8 96 Lighting Systems Body and Accessories CTSY Lamps Operate in Blackout B O Mode cont d Step Action Yes No Remove the CTSY 1 interrupt relay from the relay module Are the CTSY lamps illuminated Go to Step 8 Go to Step 7 Replace the CTSY 1 interrupt relay Did you complete the replacement Go to Step 9 E Locate and repair the short to voltage on circuit 690 8 GRY BLK Did you complete the repair Go to Step 9 5 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 Turn Signals Operate in Blackout B O Mode Step Action Yes No Schematic Reference Lighting Systems Schematics 1 Did you review Blackout B O Lighting Description and Go to Description Operation Go to Step 2 and Operation 1 Place the blackout B O service switch in blackout B O mode 2 2 Connecta test lamp at cavity C of the blackout B O switch and ground Does the test lamp illuminate Go to Step 3 Go to Step 6 1 Disconnect the blackout
109. escription Operation Go to Step 2 and Operation Connect a test lamp between cavity A of the voltmeter bulb and 2 ground Does the test lamp illuminate Go to Step 3 Go to Step 4 Connect a self powered test lamp to cavity B and ground Does the test lamp illuminate Go to Step 5 Go to Step 6 Locate and repair the open or high resistance in circuit 9 Did you complete the repair Go to Step 7 qe Replace the voltmeter bulb Did you complete the replacement Go to Step 7 mE Locate and repair the open or high resistance in circuit 150 P Did you complete the repair Go to Step 7 Eh p Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 2004 LSSV Truck Engine Engine Electrical 6 23 Voltm eter Inoperative Utility Diagnostic Aids The 24V Battery must be fully charged before testing the voltmeter for proper operation Refer to Battery Inspection Test 24V Voltmeter Inoperative Utility Step Action Yes No Schematic Reference Engine Electrical Schematics 1 Did you review the Charging System Description and Go to Description Operation Go to Step 2 and Operation 1 Disconnect the voltmeter relay 2 2 Connect a test lamp from the voltmeter relay connector terminal 87 to ground Does the test lamp illuminate Go to Step 3 Go to Step 9 Connect a test lamp from the voltmeter relay connector terminal 3 85 to
110. ess Connector C101M A 10561 10565 e 12015791 e 12010996 Connector Part Connector Part e 1 F Weather Pack 1 Way M Weather Pack Information BLK Information BLK Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function A BRN WHT 900 Blackout B O A BLK Blackout B O Marker Lamp LF Marker Lamp LF Supply Voltage Supply Voltage 2004 LSSV Truck 8 30 Wiring Systems Inline Harness C onnector C102M Body and Accessorie A 10561 10565 e 12015791 e 12010996 Connector Part Connector Part e 1 Way F Weather Pack 1 Way M Weather Information BLK Information BLK Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function A BLK m Blackout B O A TAN WHT 901 Blackout B O Headlamp Supply Headlamp Supply Voltage Voltage Inline Harness Connector C103M B A A B 10573 10574 e 12010972 e 12015793 Connector Part Connector Part e 2 Way F Weather Pack e 2 Way M Weather Pack Information SHD BLK Information TWR BLK Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function A TAN WHT 901 Blackout B O Head A TAN WHT 901 Blackout B O Head Lamp Supply Voltage Lamp Supply Voltage B BRN 900 Blackout B O B BRN 900 Blackout B O WHT Marker Lamps WHT Marker Lamps Supply Voltage Supply Voltage 2004 LSSV Truck S
111. ess to the auxiliary I P harness connector and attach the tie wraps 2 Install the forward auxiliary harness 2 to the vehicle 3 Install the auxiliary harness under the battery tray area and install the wiring harness straps 4 Install the auxiliary harness under the washer fluid reservoir area and install the wiring harness straps along the fender interior 5 Install the connector to the right hand 6 and left hand 5 blackout B O marker lamp and the ground nut to the ground lead and all wiring harness straps connecting the auxiliary harness 2004 LSSV Truck 8 46 Wiring Systems Body and Accessories 2004 LSSV Truck Install connector 4 and the ground to blackout B O headlamp mounting stud Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Install the filler panel Install the auxiliary harness connections to the original harness 10 Install the radiator grille Auxiliary Lamp Extension Harness Replacement Rear Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Access the auxiliary rear lamp extension harness from the engine compartment at the left side of the bulkhead Remove the connector 1 from the I P auxiliary harness and wiring harness straps 2 connecting to the forward lamp har
112. essories Lighting Systems 8 95 Park Lamps Operate in Blackout B O Mode cont d Step Action Yes No 1 Disconnect the blackout B O service switch connector from the switch 3 2 Connecta test lamp at cavity C of the connector and ground Does the test lamp illuminate Go to Step 5 Go to Step 4 Replace the blackout B O service switch Did you complete the replacement Go to Step 9 m 5 Locate and repair the short to voltage on circuit 912 ORN Did you complete the repair Go to Step 9 m Remove the park lamp interrupt relay from the relay module E Are the park lamps illuminated Go to Step 8 Go to Step 7 5 Replace the park lamp interrupt relay Did you complete the replacement Go to Step 9 2m Locate and repair the short to voltage on circuit 1080 WHT E Did you complete the repair Go to Step 9 m Operate the system in order to verify the repair Did you correct condition System OK Go to Step 2 CTSY Lamps Operate in Blackout B O Mode Step Action Yes No Schematic Reference Lighting Systems Schematics 1 Did you review Blackout B O Lighting Description and Go to Description Operation Go to Step 2 and Operation 1 Place the blackout B O service lamp switch in the blackout B O mode 2 2 Connect a test lamp at cavity C of the blackout B O switch and ground Does the test lamp illuminate Go to Step 3 Go to Step 6 1 Disconnect the blackout s
113. event brake damage when exposed to off road conditions Radiator Grille The radiator grille has been modified to accept the blackout B O headlamp marker lamps and the slave start receptacle The front emblem has been removed and the grille is painted 2004 LSSV Truck Body and Accessories Bumpers 8 133 Bumpers Specifications Fastener Tightening Specifications Specification Application Metric English Front Bumper Bracket Bolts Utility 63 Ib ft Front Bumper Center Bolts 90 Ib ft Front Bumper Frame Brace Bolts Utility 41 Ib ft Front Bumper Lower Support Bolts 57 lb ft Front Bumper Upper Support Bolts 23 Ib ft Front Clevis Bolts 148 lb ft Front Clevis Tie Down Support Bolts Utility 59 70 lb ft Radiator Grille Brush Guard Bolts Utility 65 Ib ft Rear Bumper Bolts Maintenance Body 59 Ib ft Rear Bumper Brace Bolts Utility 66 Ib ft Rear Bumper Frame Bolts Utility 66 Ib ft Rear Bumper Lower Bolts Maintenance Body 59 Ib ft Rear Bumper Reinforcement Bar Bolts Maintenance Body 50 Ib ft Rear Bumper Reinforcement to Bumper Bolts 59 Ib ft Rear Bumper Reinforcement to Frame Bolts 87 Ib ft Rear Bumper Side Frame Bolts 87 Ib ft Rear Bumper Side Frame Bolts Maintenance Body 87 Ib ft Rear Bumper Side Reinforcement Bolts 59 Ib ft Rear Bumper Tie Down Plate Bolts Maintenance Body 59 Ib ft Rear Clevis Bolts 148 Ib ft Rear Clevis Tie Down Support Side Bolts Utility 57 Ib ft Rear Clevis Tie Down Support Vertical Bolt Utili
114. f the power converter is used to obtain 24 volts in a predominately 12V system The power converter can deliver up to 100 amps of continuous clean 24V current for practically any 24V load such as two way radios navigations blackout B O lighting and other military options Caution 24V loads drawing current in excess of the rating of the Converter are permissible for short periods of time minutes only Prolonged use of these loads will result in improper battery charge and eventual battery deterioration and possible damage to the converter DO NOT WELD ON VEHICLES EQUIPPED WITH CONVERTER SYSTEM PERMANENT DAMAGE MAY RESULT TO THE CONVERTER SYSTEM REMOVE ALL CONVERTER FUSES BEFORE WELDING 2004 LSSV Truck 6 44 Engine Electrical Engine 24V Voltmeter A voltmeter is installed to monitor the status of the 24V battery and the 24V generator pickup or the power converter utility Pickup Voltage is available through circuit 8008 BRN of the 24V 10A fuse When the vehicle load disconnect switch is placed in the ON position voltage is applied to the 24V fuse that provides voltage to the voltmeter The voltmeter is grounded at G200 through the I P relay block Utility Voltage is available through circuit 901 ORN wire of the voltmeter relay When the ignition switch is placed in the ON position voltage is applied to the power converter 24V regulator that provides voltage to the voltmeter relay The voltmeter is grounded
115. fer to Winch Connector Harness Replacement Rear in Wiring Systems 11 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 12 Install the clevis tie down Tie Down Plate Replacement Rear Maintenance Body Removal Procedure 1 Remove the rear hitch and reinforcement plate Refer to Trailer Hitch Reinforcement Plate Replacement Maintenance Body in Frame and Underbody 2 Remove the rear bumper Refer to Bumper Replacement Rear Maintenance Body 3 Remove the rear bumper reinforcement Remove the 4 upper and 2 lower tie down plate bolts 5 Remove the 6 remaining bolts and the tie down plate Installation Procedure 1 Position the tie down plate to the frame rail 2 Install the 6 side frame rail to bracket bolts Note Do not tighten at this time 3 Install the 4 upper and 2 lower tie down plate bolts 4 Install the rear bumper reinforcement bar Refer to Rear Bumper Reinforcement Bar Replacement Notice Refer to Fastener Notice in Cautions and Notices Important Tighten the mounting bolts in the following sequence Tighten Tighten the 6 side frame rail bracket bolts to 117 Nem 87 Ib ft Tighten the 4 upper and 2 lower tie down plate bolts to 79 Nem 59 Ib ft Body and Accessories Bumpers 8 153 5 Install the rear bumper Refer to Bumper Replacement Rear Maintenance Body 6 Install the rear hitch and reinforcement plate Refer to
116. fuse block Engine Electrical Connector End Views in Engine Electrical Generator Fuses 24V In the engine compartment inline with the 24V generator harness Engine Electrical Connector End Views in Engine Electrical Headlamp Hi and Low Beam Interrupt Relay Interrupt relay block RH engine compartment Engine Electrical Component Views in Engine Electrical Horn Interrupt Relay Interrupt relay block RH engine compartment Engine Electrical Component Views in Engine Electrical Interrupt Relay Block RH of engine compartment on the underhood fuse block Engine Electrical Component Views in Engine Electrical Junction Block Park Lamp Interrupt Relay Left of RH battery mounted on the bulkhead Interrupt relay block RH engine compartment Engine Electrical Component Views in Engine Electrical Engine Electrical Component Views in Engine Electrical Power Converter Rear body panel behind the seat Utility Engine Electrical Component Views in Engine Electrical Trailer Harness Connector 12 Pin Near the center of the rear bumper Lighting Systems Component Views in Lighting Systems Lighting Systems Connector End Views in Lighting Systems Turn Signal Interrupt Relay Interrupt relay block RH engine compartment Lighting Systems Component Views in Lighting Systems C100M 1 Cavity Front left of the front bumper for left front blackout B O marker
117. g Component Views Rear Lamp Harness Legend 1 C908M 6 C901M 2 Auxiliary Rear Lamp Extension Harness 7 C900M 3 Rear of Vehicle 8 C903M 4 Rear Taillamp Connectors 9 G901M 5 C902M 2004 LSSV Truck 8 18 Wiring Systems Body and Accessories Forward Blackout B O Lamp Harness Legend 1 I P Wiring Harness 4 C102M 2 Forward Lamp Harness 5 C101M 3 G100M 6 C100M 2004 LSSV Truck Body and Accessories Wiring Systems 8 19 Voltmeter and Lamp Legend 1 Voltmeter 24V 4 Bracket 2 Voltmeter Connector 5 Harness Connector 3 Accessory Panel 6 Voltmeter Illumination Bulb 2004 LSSV Truck 8 20 Wiring Systems Body and Accessories Slave Receptacle Harness Routing Legend 1 Slave Receptacle 3 Negative Connection to Engine Block 2 Negative Cable 4 Positive Cable to Junction Block 2004 LSSV Truck Body and Accessories Wiring Systems 8 21 Slave Receptacle Harness Routing Utility Legend 1 Slave Receptacle 3 Negative Connection to Engine Block 2 Negative Cable 4 Positive Cable to 24V Battery 2004 LSSV Truck 8 22 Wiring Systems Body and Accessories Power Converter Legend 1 Ground Terminal 4 Fuse Link Covers 2 12V Terminal 5 Ignition Terminal 3 24V Terminal 6 Power Converter 2004 LSSV Truck Body and Accessories Wiring Systems 8 23 Relay Block I P Legend 1 Cavity C Blackout B O Switch C4
118. gine Remove the drive belt Refer to Drive Belt Replacement in Engine Mechanical 6 6 L in 2004 C K Truck Service Manual Spin the generator pulley by hand Does the generator shaft spin smoothly and without any roughness or grinding noise Go to Step 4 Go to Step 10 Inspect the generator for a loose pulley and or pulley nut Is the generator pulley or pulley nut loose Go to Step 10 Go to Step 5 Inspect the generator for the following conditions e Strained or stretched electrical connections e Hoses or other vehicle equipment resting on the generator which may cause the noise to be transmitted into the passenger compartment Are any electrical connections pulling on the generator or are any hoses etc resting on the generator Go to Step 6 Go to Step 7 Reroute the electrical connections to relieve the tension Reroute the hoses etc away from the generator Start the engine Has the noise decreased or stopped System OK Go to Step 7 Inspect the drive belt for proper tension Refer to Drive Belt Tensioner Diagnosis in Engine Mechanical 6 6 L in 2004 C K Truck Service Manual Is the drive belt loose Go to Step 8 Go to Step 9 2004 LSSV Truck 6 26 Engine Electrical Engine 24V Generator Noise Diagnosis cont d Sep tion ___ Ye 1 Replace the drive belt tensioner Refer to Drive Belt Tensioner Replacement in Engine Mechanical 6 6L in 2004 C K Truck Service Manual 2 Start the engine Has th
119. ground Does the test lamp illuminate Go to Step 4 Go to Step 10 Connect a test lamp between the voltmeter relay connector 4 terminals 87 and 86 Does the test lamp illuminate Go to Step 5 Go to Step 11 Connect a 15A fused jumper between the voltmeter relay 5 connector terminals 87 and 30 Does the voltmeter function Go to Step 14 Go to Step 6 1 Reconnect the voltmeter relay 2 Disconnect the voltmeter 6 3 Connect a test lamp from the voltmeter connector terminal B to battery voltage Does the test lamp illuminate Go to Step 7 Go to Step 12 Connect a test lamp from the voltmeter connector terminal A to 7 ground Does the test lamp illuminate Go to Step 8 Go to Step 13 1 Inspect the voltmeter for a poor connection 2 Ifthe connection is OK replace the voltmeter Refer to 8 Voltmeter Replacement in Instrument Panel Gages and me Console Is the replacement complete Go to Step 15 Repair an open or a poor connection in circuit 901 between the voltmeter relay terminal 87 and the 24V terminal of the power 9 converter EN Is the repair complete Go to Step 15 Repair an open or a poor connection in circuit 739 between the voltmeter relay terminal 85 and the IGN terminal of the power 10 converter EET Is the repair complete Go to Step 15 2004 LSSV Truck 6 24 Engine Electrical Engine Voltmeter Inoperative Utility cont d Step Action Yes No Repair an open or a poo
120. harging Connector End Views Voltmeter Connector Engine Generator Connector 10547 Connector Part e 02973781 Information e 2 Way Series 280 BLK Wire Circuit No Function Pin Color A BRN 8008 Voltmeter Supply Voltage B BLK 150 Ground Voltmeter Lamp A B 7927 Connector Part e 12004264 intermeavon 2F LP SOC Hardshell BLK Wire Circuit No Function Pin Color A BRN 9 Voltmeter Supply Voltage B BLK 150 Ground 2004 LSSV Truck 7862 Connector Part e 15355066 Information e 4 Metri Pack 150 Series Sealed NAT Pin Wire Circuit No Function Color mt Not Used B YEL 8014 Generator Field Duty Cycle Signal C D m Not Used 24V Generator Relay 85 10550 Connector Part e 12129716 Information 4 Way F MP Series 280 GRY Pin Wire Circuit No Function Color 30 BRN 8008 Operator Field Duty Cycle Signal 85 PNK 8002 UBEC Cavity A3 86 BLK 150 Ground 87 RED BLK 8009 24V Battery Supply Voltage Engine Engine Electrical 6 21 24V Trailer Fuse Multi Mount Winch Prep Connector Front B A 10567 Connector Part e 12010105 Information e 2 Way Auto Fuse Holder Pin Wire Circuit No Function Color A RED BLK 8009 24V Battery Voltage B RED WHT 802 Trailer Connector Supply Voltage B A 10804 Connect
121. iagnostic Information and Procedures Symptom List Refer to a symptom diagnostic procedure from the following e Blackout B O Headlamp Inoperative list in order to diagnose the symptom e Blackout B O Headlamp Always On e Headlamps Operate in Blackout B O Mode e Backup Lamps Inoperative e Blackout Stoplamps Inoperative Blackout Marker Lamps Inoperative Blackout B O Marker Lamps Always On DRL Operate in Blackout B O Mode Backup Lamps Operate in Blackout B O Mode Park Lamps Operate in Blackout B O Mode CTSY Lamps Operate in Blackout B O Mode Turn Signals Operate in Blackout B O Mode Hi Beam Headlamps Operate in Blackout B O Mode Low Beam Headlamps Operate in Blackout B O Mode Blackout B O Headlamp Inoperative 2004 LS Step Action Yes No Schematic Reference Lighting Systems Schematics 1 Did you review Blackout B O Lighting Description and Go to Description Operation Go to Step 2 and Operation Inspect condition of fuses If fuse is open locate and repair 2 source of overload and replace fuse Did you find and correct the condition Go to Step 20 Go to Step 3 1 Place blackout B O service switch in blackout B O mode Turn ON blackout B O headlamp switch 3 Connect a test lamp to circuit 901 TAN WHT at connector C102M cavity A of the blackout B O headlamp and ground Does the test lamp illuminate Go to Step 4 Go to Step 7 1
122. ighten negative connections to 6 Nem 53 Ib in Install the rubber cover onto the rear of the positive cable connection Position the slave receptacle cover onto the rear of the bracket Install the fasteners 3 onto the slave receptacle 2 and the slave receptacle rear connector cover 1 Tighten Tighten bolts to 8 Nem 71 Ib in Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2004 LSSV Truck 8 140 lt Body and Accessories 2004 LSSV Truck Radiator Grille Brush Guard Replacement Note The grille brush guard and front bumper are replaced as a unit If damaged refer to Bumper Replacement Front Radiator Grille Brush Guard Replacement Utility Removal Procedure 1 Remove the 2 bolts 1 washers and nuts holding the brush guard to upper supports 2 Remove the blackout B O marker lamps Refer to Marker Lamp Replacement Front Blackout B O Utility in Lighting Systems 3 Remove lower fasteners 2 from the bumper 4 Remove the radiator grille brush guard assembly 3 Installation Procedure 1 Install the radiator brush guard assembly 3 Notice Refer to Fastener Notice in Cautions and Notices 2 Install the brush guard to the front bumper with the 3 fasteners 2 washers spacers and nuts Tighten Tighten the 3 fasteners to 88 N m 65 Ib ft 3 Install the 2 bolts 1 washers and nuts to the upper supp
123. ination ON OFF Radio Clock ILLUMINATION ON OFF Headlamp High Beam Indicator ON OFF Turn Signal Hazard Warning Indicators ON OFF Four Wheel Drive Indicator ON OFF Dome Courtesy Lamps ON OFF Glove Compartment Lamp ON OFF Underhood Lamp ON OFF Warning Chime Headlamps On Safety ON ON OFF Belt and Key in Ignition Interior Lights Mechanical Device Service Switch Blackout B O Drive Light Switch Brake Transmission Shift Interlock ON ON OFF BTSI Torque Converter Lockup Clutch ON ON OFF 2004 LSSV Truck 8 116 Lighting Systems Body and Accessories BLANK 2004 LSSV Truck Body and Accessories Instrument Panel Gages and Console 8 117 Instrument Panel Gages and Console Specifications Fastener Tightening Specifications Specification Application Metric English Accessory Panel Bolts 8 Nem 71 Ib in Blackout B O Switch Nuts 2 8 Nem 24 Ib in Voltmeter Nuts 2 8 Nem 24 Ib in 2004 LSSV Truck 8 118 Instrument Panel Gages and Console Body and Accessories BLANK 2004 LSSV Truck Body and Accessories Instrument Panel Gages and Console 8 119 Repair Instructions Voltmeter Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 2 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Remove the accessory panel Refer to Accessory Panel Repla
124. ing Systems Body and Accessories Blackout B O Stoplamps Inoperative Step Action Yes No Schematic Reference Lighting Systems Schematics 1 Did you review Blackout B O Lighting Description and Go to Description Operation Go to Step 2 and Operation Observe the stoplamps while pressing the brake pedal Go to Testing for Electrical 5 Does the system operate normally Intermittents Wiring Systems of the 2004 C K Truck Service Manual Go to Step 3 Inspect the fuse s check for damaged or corroded inline connectors check for broken or partially broken wires inside 3 insulation and properly installed aftermarket equipment Did you find the condition Go to Step 4 Go to Step 5 Make necessary repairs Did you complete the repairs Go to Step 15 B 5 Are all the stoplamps inoperative Go to Step 6 Go to Step 8 1 Disconnect blackout B O service lamp switch 6 2 Connecttest lamp between circuit 913 WHT cavity D wire and ground Does the test lamp illuminate Go to Step 10 Go to Step 7 E Locate and repair the open or high resistance in circuit 913 Did you correct the condition Go to Step 15 m Test the supply voltage circuit of the inoperative lamp for high resistance an open or a short to ground Refer to 8 Circuit Testing and Wiring Repairs in Wiring Systems in the 2004 C K Truck Service Manual Did you find and correct the condition Go to Step 15 Go to Step 9 Test the ground circuit
125. ing nuts and bolts 5 Remove the nuts holding the 24V and 12V cables to the switch and remove the cables Note location of cables removed for assembly Installation Procedure 1 Install the 24V and 12V cables to the switch Red cable from 24V battery positive 1 to terminal 4 Red black cable 4 from 24V generator to terminal 3 Red cable 3 from UBEC to terminal 1 Red cable 2 from 24V battery negative to terminal 2 Notice Refer to Fastener Notice in Caution and Notices 2 Install the switch to the underhood electrical center cover Tighten Tighten the switch mounting nuts to 9 Nem 80 Ib in 2004 LSSV Truck 6 40 Engine Electrical Engine 2004 LSSV Truck 3 Set electrical center cover assembly in its resting position until the tabs 3 lock into place 4 Install the fender upper brace and the disconnect switch key 5 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure 24 Voltmeter Relay Replacement Utility Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Remove the negative cable of the right battery and the 12V and 24V cable of the left battery 2 Remove the cover from the trim panel 3 Remove the relay 2 from the connector 1 Installation Procedure 1 Install the relay 2 into the connector 1 2 Install the cover onto the trim panel 3 Connect the battery cables Refer to Battery Cable Disconne
126. ion until the tabs 3 lock into place 4 Install the electrical center cover assembly 1 5 Install the top cover 2 6 Install the fender upper brace Notice Refer to Fastener Notice in Cautions and Notices 7 Install the upper brace fasteners Tighten Tighten the fasteners to 25 Nem 18 Ib ft 8 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2004 LSSV Truck 8 52 Wiring Systems Body and Accessories Blackout B O and Trailer Harness Replacement Rear Removal Procedure Caution Refer to Battery Disconnect Caution in Caution and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2 Disconnect the 2 24V trailer harness connectors 5 from the 24V trailer connector harness 3 Disconnect the 3 blackout B O and trailer harness connectors 2 4 Disconnect the 2 blackout B O marker lamp connectors 1 from the blackout B O marker lamps 5 Remove the 2 bolts 3 and 2 clamps 4 from the blackout B O and the trailer harness 6 Remove the blackout B O and the trailer harness from the bumper assembly Installation Procedure 1 Position the blackout B O and the trailer harness onto the bumper in the same routing location as removed 2 Install the 2 clamps 4 and the 2 bolts 3 to the blackout B O and trailer harness 3 Connect the 2 blackout marker lamp connectors
127. lam rate normally 20774 2 SNE marKe ps operaie Intermittents Wiring Systems of the 2004 C K Truck Service Manual Go to Step 3 3 Are all marker lamps inoperative Go to Step 4 Go to Step 8 Inspect the fuse s check for corroded inline connectors check for broken or partially broken wires inside insulation 4 and for properly installed aftermarket equipment Did you find the condition Go to Step 5 Go to Step 6 5 Make necessary repairs Did you complete the repairs Go to Step 14 1 Place blackout B O service switch in blackout B O mode 6 2 Connect a test lamp at cavity A circuit 911 PNK wire at blackout B O service drive switch and ground Does the test lamp illuminate Go to Step 7 Go to Step 14 Connect a test lamp between inline fuse cavity B circuit 911 7 PNK wire and ground Does the test lamp illuminate Go to Step 11 Go to Step 10 Test the supply circuit of the inoperative lamp for high resistance or an open Refer to Circuit Testing and Wiring 8 Repairs in Wiring Systems in the 2004 C K Truck Service Manual Did you find and correct the condition Go to Step 18 Go to Step 9 Test the ground circuit of the inoperative lamp for high resistance or an open Refer to Circuit Testing and Wiring 9 Repairs in Wiring Systems in the 2004 C K Truck Service Manual Did you find and correct the condition Go to Step 18 Go to Step 12 2004 LSSV Truck 8 92 Lighting Systems Body and Accessories Blackout B O Marker
128. le Disconnect Connect Procedure in Engine Electrical 2004 LSSV Truck 8 122 Instrument Panel Gages and Console Body and Accessories Description and Operation Instrument Panel and Gages Description The instrument panel has been modified with an accessory panel mounted below the accessory power outlets This panel houses the blackout B O lighting auxiliary switches and 24V meter 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 2004 LSSV Truck Body and Accessories Horns 8 123 Horns Schematic and Routing Diagrams 2004 LSSV Truck Body and Accessories 8 124 Horns soneuieuos uonnquisiq punolg 216 WEOES jnoxoelg JONIL v00c 01 poouJepur SN4 pejoeuuoosiq Buysixg N49 9 0 i yoolg asni SuJoH 2004 LSSV Truck Body and Accessories Horns 8 125 Diagnostic Information and Procedures Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom e Horns Inoperative e Horns Operate in Blackout B O Mode Horns Inoperative Step Action Yes No Schematic Reference Horn Schematics 1 Did you review Horns Description and Operation Go to Descriptio
129. llation Procedure Install the parts removed from the accessory panel Refer to Voltmeter Replacement or Blackout B O Switch Replacement Install the connectors 2 to the blackout B O switches Install the connector and bulb 1 to the 24V meter Install the switch panel 2 onto the dash Notice Refer to Fastener Notice in Cautions and Notices Install the fasteners 1 and tighten Tighten Tighten switch panel bolts to 8 Nem 71 Ib in Body and Accessories Instrument Panel Gages and Console 8 121 Blackout B O Switch Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2 Remove the accessory panel Refer to Accessory Panel Replacement 3 Remove the nuts 1 and washers holding the blackout B O switches 4 Remove the keyed washers from the accessory panel and pull the switches out BLACKOUT DRIVE LIGH7 Installation Procedure 1 Install the switches through the accessory panel 2 Install the keyed washers on the switches Notice Refer to Fastener Notice in Cautions and Notices 3 Install the 2 washers and nuts 1 on the panel BLACKOUT Tighten DRIVE LIGH7 Tighten the 2 nuts to 2 8 N m 24 Ib in 4 Install the accessory panel Refer to Accessory Panel Replacement in Instrument Panel 5 Connect the battery cables Refer to Battery Cab
130. ly to reduce the risk of personal injury during service or repair Improper service or repair may damage the vehicle or render the vehicle unsafe For Cautions and Notices refer to 2004 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 2004 General Motors LSSV Military Trucks Service Manual Supplement This manual provides information on the diagnosis the service procedures the adjustments and the specifications for the 2004 GM LSSV Base Pickup Crew Cab and Utility Information on transmission unit repair overhaul can be found in the 2004 Transmission Transaxle Transf
131. ment 8 160 Repair Floor Mat Replacement 8 161 Government Vehicle Data Plate Replacement esses 8 160 Specifications Fastener Tightening Specifications 8 159 J Jump Starting in Case of Emergency 6 31 L Label 24V Battery Caution 0 6 Equalizer Label eee 0 6 Shipping Data 0 7 Vehicle Identification Plate 0 6 Vehicle Load Disconnect Switch Caution Label 0 6 Lamp Harness Replacement Rear 8 47 Lamp Replacement Repair Lamp Replacement Voltmeter 8 107 License Plate Bracket Replacement Utility 8 111 License Plate Lamp Repair License Plate Lamp Replacement PICKUP ERR eim nsa 8 109 License Plate Lamp Replacement Utility 8 111 Lighting Systems Components Lighting Systems Component Views 8 71 Lighting Systems Connector End Views 8 83 Description Blackout B O Lighting Circuit Operation 8 114 Diagnosis Backup Lamps 8 88 Backup Lamps Operate in Blackout B O vied T 8 94 Blackout Headlamp Always On 8 88 Blackout Headlamp Inoperative 8 86 Blackout B O Marker
132. mounting location using the wiring harness strap 4 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Marker Lamp Replacement Front Blackout B O Utility Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 2 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Remove the bolt 1 on the brush guard and slide out the blackout B O marker light assembly from the grille Remove the harness connector 2 by releasing the connector tab Remove the nut holding the ground lead to the lamp stud Remove the nuts holding the lamp to the mounting bracket Remove the blackout B O marker lamp assembly 1 Body and Accessories Lighting Systems 8 103 Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 1 Install the mounting bracket to the blackout marker lamp assembly 1 Tighten Tighten marker lamp nuts to 2 Nem 18 lb in 2 Install the ground lead to the blackout marker lamp stud Tighten Tighten ground lead nut to 2 Nem 18 lb in 3 Install the harness connector 2 to the marker lamp connector 4 Install the marker lamp assembly into the opening in the grille and install the bolt 1 to the brush guard 5 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical
133. move the cover 3 and trailer connector 2 Installation Procedure 1 Install the trailer connector 2 and cover 3 onto the bumper Notice Refer to Fastener Notice in Cautions and Notices Install the fasteners to secure the cover and connector to the bumper Tighten Tighten connector bolts to 5 Nem 44 Ib in Connect the harness connectors 1 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Relay Mounting Bracket Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 2 e Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Remove the left fender upper brace Remove top cover 2 Remove the electrical center cover assembly 1 by lifting the cover outwards to clear the tabs 3 Remove the vehicle load disconnect switch if equipped Refer to Vehicle Load Disconnect Switch Replacement in Engine Electrical Body and Accessories Wiring Systems 8 51 Caution Refer to Eye Protection Caution in Cautions and Notices 6 Drill out the rivets 2 and remove bracket 1 Installation Procedure 1 Rivet the bracket 1 to the electrical center cover 2 Install the vehicle load disconnect switch if equipped Refer to Vehicle Load Disconnect Switch Replacement in Engine Electrical 3 Setthe electrical center block in its resting posit
134. mp between connector C1 cavity C of the junction block rear lamps and ground Does the test lamp illuminate Go to Step 7 Go to Step 9 Connect a test lamp between connector C1 cavity E and ground Does the test lamp illuminate Locate and repair the open or high resistance in the ground circuit Did you complete the repair Go to Step 8 Go to Step 17 Go to Step 13 Connect a test lamp between cavity 30 of the interrupt relay and ground Does the test lamp illuminate Go to Step 10 Go to Step 11 Locate and repair the open in circuit 24 Did you complete the repair Go to Step 17 Connect a test lamp between cavity 87 of the interrupt relay and ground Does the test lamp illuminate Go to Step 14 Go to Step 12 Connect a test lamp between cavity F of the backup lamp switch and ground Does the test lamp illuminate Go to Step 15 Go to Step 16 Replace the bulbs Did you complete the replacement Go to Step 17 Replace the interrupt relay Did you complete the replacement Go to Step 17 Locate and repair the open or high resistance in circuit 1524 or 24 Did you complete the repair Go to Step 17 Replace the backup lamp switch Did you complete the replacement Go to Step 17 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 2004 LSSV Truck 8 90 Light
135. mp between the converter GND terminal and 16 ground Does the test lamp illuminate Go to Step 21 Go to Step18 Connect a test lamp between the input stud of the 24V circuit 17 breaker and ground Does the test lamp illuminate Go to Step 22 Go to Step 23 Replace the power converter Refer to Power Converter 18 Replacement Utility Did you complete the replacement Go to Step 24 46 Locate and repair the open or high resistance in circuit 739 Did you complete the repair Go to Step 24 n Locate and repair the open or high resistance in circuit 900 Did you complete the repair Go to Step 24 54 Locate and repair the open or high resistance in circuit 150 Did you complete the repair Go to Step 24 Inspect for the following conditions e High resistance or short to ground on circuit 900 SE e Faulty or weak 24V circuit breaker Did you find and correct the condition Go to Step 24 95 Locate and repair the open or high resistance in circuit 900 Did you complete the repair Go to Step 24 54 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 2004 LSSV Truck 6 30 Engine Electrical Engine Power Converter Test Notice Do not let the converter terminal contact any surface This will cause an electrical short and may damage the converter or the vehicle 1 2 3 Clean and tighten converter connections Start
136. mper onto the vehicle 2004 LSSV Truck 8 144 lt Body and Accessories 2004 LSSV Truck 8 Install the 6 side frame rail to bracket bolts nuts Note Do not tighten at this time Notice Refer to Fastener Notice in Cautions and Notices 9 Install the 4 bumper reinforcement bolts Important Tighten the rear bumper mounting bolts in the following sequence Tighten Tighten the 6 side frame rail bracket bolts nuts to 117 Nem 87 lb ft Tighten the 4 side bumper reinforcement bracket bolts nuts to 79 Nem 59 Ib ft 10 Connect the trailer wiring harness Refer to Blackout B O and Trailer Harness Replacement Rear in Wiring System 11 Install the winch connector Refer to Winch Connector Harness Replacement Rear in Wiring Systems 12 Remove the support 13 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 14 Install the pintle hook Refer to Pintle Hook Replacement Bumper Reinforcement Rear Removal Procedure 1 Remove the 2 rear bumper reinforcement to bracket nuts bolts 2 Remove the 3 rear bumper reinforcement to frame nuts bolts 3 Remove the rear bumper reinforcement bracket 1 Body and Accessories Bumpers 8 145 Installation Procedure 1 Position the rear bumper reinforcement bracket 1 onto the vehicle 2 Install the 2 bumper reinforcement to bracket nuts bolts Note Do not tighten at this
137. n Go to Step 2 and Operation Depress the horn switch Go to Horns Inoperative One 2 2 Does either horn Operate Horn Horns of the 2004 C K Truck Service Manual Go to Step 3 1 Remove the horn interrupt relay Go to Horns 3 2 Connect a jumper between terminal 30 and 87 of the E ee relay block ot the E Truck Service Does either horn operate Go to Step 4 Manual Connect a test lamp between terminal 86 of the relay block 4 ground Does the test lamp illuminate Go to Step 6 Go to Step 5 Connect a test lamp between terminal C of the blackout 5 B O service switch and ground Does the test lamp illuminate Go to Step 7 Go to Step 8 Connect a test lamp between terminal 85 of the relay block 6 and ground Does the test lamp illuminate Go to Step 9 Go to Step 10 gt Repair the open or high resistance in the ORN circuit 912 Did you complete the repair Go to Step 13 Connect a test lamp between terminal of the blackout 8 B O service switch and ground Does the test lamp illuminate Go to Step 11 Go to Step 12 S Repair the open or high resistance in the BLK circuit 150 Did you complete the repair Go to Step 13 nmi i Replace the horn interrupt relay Did you complete the repair Go to Step 13 zm Replace the blackout B O service switch Refer to Blackout B O Switch Replacement in Instrument Panel Gages and 11 Console Did you complete the replacement Go to Step 13 2004 LSSV Truck 8 126 Ho
138. n Lighting Systems Remove the military trailer connector Refer to Military Trailer Connector Replacement in Lighting Systems Remove the commercial trailer connector Refer to Commercial Trailer Connector Replacement in Wiring Systems Installation Procedure 1 2 Install the marker lamps Refer to Marker Lamp Replacement Maintenance Body Install the taillamps Refer to Taillamp Replacement Maintenance Body Install the blackout B O marker lamps Refer to Marker Lamp Replacement Rear Maintenance Body in Lighting Systems Install the military trailer connector Refer to Military Trailer Connector Replacement in Lighting Systems Install the commercial trailer connector Refer to Commercial Trailer Connector Replacement in Wiring Systems Install the trailer wiring harness Refer to Blackout B O and Trailer Harness Replacement Rear in Wiring Systems Using the aid of an assistant position the rear bumper onto the vehicle by sliding it on to the tie down plates 15684 15684 2004 LSSV Truck 8 152 Bumpers Body and Accessories 2004 LSSV Truck Notice Refer to Fastener Notice in Cautions and Notices 8 Install the 4 bumper bolts 1 right side shown left side similar Tighten Tighten the bumper bolts to 79 N m 59 Ib ft 9 Connect the trailer wiring harness Refer to Blackout B O and Trailer Harness Replacement Rear in Wiring System 10 Install the winch connector Re
139. nd Accessories Lighting Systems 8 75 Rear Blackout B O Lamps Utility Legend 1 Blackout B O Lamp Assembly 3 Rear Lamp Harness Connector 2 Rear Bumper 2004 LSSV Truck 8 76 Lighting Systems Body and Accessories Front Blackout B O Marker Lamps Pickup JW Legend 1 Front Bumper 3 Forward Lamp Harness 2 Blackout B O Lamp Assembly 2004 LSSV Truck Body and Accessories Lighting Systems 8 77 Front Blackout B O Marker Lamps Utility Legend 1 Blackout B O Lamp Assembly 3 Forward Lamp Harness 2 Front Grille 2004 LSSV Truck 8 78 Lighting Systems Front Lighting Pickup Body and Accessorie Legend 1 Blackout B O Headlamp 2 Headlamp Harness Connector 3 Blackout B O Marker Lamp Fastening Nuts 4 Marker Lamp Harness Connector 2004 LSSV Truck 5 6 7 8 Marker Lamps Headlamp Fastening Nut Washer 8 Headlamp Ground Lead 2 Ta Body and Accessories Lighting Systems 8 79 Blackout B O Headlamp Utility Legend 1 Brace Assembly 4 Ground Lead 2 Blackout B O Headlamp 5 Headlamp Stud Nut 3 Wiring Harness Connector 2004 LSSV Truck 8 80 Lighting Systems Body and Accessories Rear Lighting Pickup Legend 1 License Plate Lamp 6 Trailer Connector Military 2 Trailer Harness Connector Commercial 7 Trailer Connector Cover 8 9 Trailer Connector Commercial
140. ness Caution Refer to Vehicle Lifting Caution in Cautions and Notices 4 Raise and support the vehicle on a hoist 5 Trace the auxiliary rear lamp harness extension along the path of the existing harness and vehicle frame 6 Remove the connector to the rear lamp harness Body and Accessories Wiring Systems 8 47 Installation Procedure 1 2 3 Install the connector to the rear lamp harness Install the auxiliary rear lamp harness extension along the path of the existing harness and vehicle frame Remove supports and lower the vehicle Install the connector 1 to the I P auxiliary harness and wiring harness straps 2 holding to the forward lamp harness Install the auxiliary rear lamp extension harness to the engine compartment location at the left side of the bulkhead Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Lamp Harness Replacement Rear Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 2 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Remove the rear lamp harness connector from the taillamp connector Remove the ground lead and connector for the blackout B O marker lamp Remove the vehicle ground lead bolt washer and harness ground Remove the rear lamp harness connector from the auxiliary rear lamp extension harness Remove th
141. of that first If you don t explosive gas could be present Don t get it on you If you accidentally get it in your eyes or on your skin flush the place with water and get medical help immediately Caution Fans or other moving engine parts can injure you badly Keep your hands away from moving parts once the engine is running 4 Connect the slave cable to the vehicle with the dead battery 5 Startthe vehicle with the good batteries 6 Connect the slave cable to the vehicle with the good 7 battery YD SZ 005925 7 Allow the vehicle with the dead battery to charge for 10 KX X minutes NZ 2 L lt lt Note It may take up 30 minutes to charge the battery enough DC CX to start the vehicle depending on its state of charge 8 Startthe vehicle with the dead battery 9 Remove the slave cable in the reverse order that it was installed Take care not to let the cables touch a metal surface Circuit Breaker Replacement 12V or 24V Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure 2 Remove the nuts holding the wires to the circuit breaker and remove the wires Note the location of wires for reassembly 3 Remove the 2 bolts 1 holding the 12V 2 or 24V 3 circuit breaker to the fender support 4 Remove the 12V 2 or 24V 3 circuit breaker 2004 LSSV Truck Engine
142. ole Install spring clip 2 into retaining pin gt 2004 LSSV Truck Body and Accessories Bumpers 8 149 Clevis Tie Down Replacement Rear Military Bumper Removal Procedure 1 Remove the nut 3 and bolt 1 2 Remove the clevis 2 from frame Installation Procedure 1 Install the clevis 2 to frame Notice Refer to Fastener Notice in Cautions and Notices Notice Clevis must move once torqued Do not over torque 2 Install the bolt 1 and nut 3 Tighten Tighten the nut and bolt to 200 Nem 148 lb ft Clevis Tie Down Bracket Replacement Rear Utility Removal Procedure 1 Remove the rear clevis Refer to Clevis Tie Down Replacement Rear Utility 2 Remove bolt 2 from clevis mount 3 Remove nuts and bolts 1 from clevis mount 4 Remove clevis mount 3 from frame 2004 LSSV Truck 8 150 Bumpers Body and Accessories Installation Procedure 1 Install clevis mount s to frame Notice Refer to Fastener Notice in Cautions and Notices 2 Install bolts 1 and tighten Tighten Tighten bolts to 77 N m 57 Ib ft 3 Install bolt 2 and tighten Tighten Tighten bolt to 102 Nem 75 Ib ft 4 Install the rear clevis Refer to Clevis Tie Down Replacement Rear Utility Clevis Tie Down Replacement Rear Utility Removal Procedure 1 Remove the nut 1 and bolt 2 2 Remove the clevis 3 from frame Installation Procedure 1 Install the clevis
143. onnector Part 12010996 1 Way M Weather Pack Information BLK Information BLK Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function A ORN 912 Supply Voltage to A ORN 912 Supply Voltage to Relay Module Relay Module Inline Harness Connector C108M 10572 55 10571 Connector Part 12105792 2 Way F Weather Pack Connector Part 12010973 2 Way M Weather Pack Information TWR BLK Information TWR BLK Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function A BRN WHT 900 Rear Marker Lamp A BRN WHT 900 Rear Marker Lamp Supply Voltage Supply Voltage B DK 902 Rear Stoplamp B DK 902 Rear Stoplamp GRN WHT Supply Voltage GRN WHT Supply Voltage 2004 LSSV Truck S ody and Accessories Wiring Systems 8 3 Inline Harness Connector C301M pg aD SN 14634 14635 Connector Part e 12052641 Connector Part e 12162000 Information e 2 Way F M P 150 Series Information e 2 Way M M P 150 Series Wire Circuit Wire Circuit 3 Pin Color No Function Pin Color No Function A BRN WHT 803 To Rear Topper A BRN 800 From Front Topper Dome Switch Dome Switch B BRN 800 To Rear Topper B BRN WHT 803 From Front Topper Dome Switch Dome Switch Inline Harness Connector C302M CSS SSC B A 14637 14636 e 12129
144. or Part e 017639 Information 2 Way RED Wire Circuit No Function Pin Color A BLK RED 1 Supply Voltage B BLK 150 Ground 24V Auxiliary Fuse Multi Mount Winch Prep Connector Rear Fara B A 10567 Connector Part e 12010105 Information e 2 Way Auto Fuse Holder Pin Wire Circuit No Function Color RED BLK 8009 24V Battery Voltage B RED BLK 8009 24V Feed Not Used B A 10804 Connector Part e 017640 Information 2 Way RED Wire Circuit No Function Pin Color A BLK RED 1 Supply Voltage B BLK 150 Ground 2004 LSSV Truck 6 22 Engine Electrical Engine Diagnostic Information and Procedures e Voltmeter Inoperative Utility e Voltmeter Inaccurate or Inoperative Pickup Symptom List aa 24V Generator Noise Diagnosis Note For vehicle no start condition refer to Diagnostic System Check in Engine Controls 6 6L in the 2004 C K Truck Service Manual e Battery Inspection Test e 24V Generator Inoperative Pickup Refer to a symptom diagnostic procedure from the e Power Converter Inoperative Utility following list in order to diagnose the symptom e Power Converter Test e Voltmeter Lamp Inoperative Voltmeter Lamp Inoperative Voltmeter Lamp Inoperative Step Action Yes No Schematic Reference Engine Electrical Schematics 1 Did you review the Charging System Description and Go to D
145. orts and tighten Tighten Tighten the bolts to 88 N m 65 Ib ft 4 Install the blackout B O marker lamps Refer to Marker Lamp Replacement Front Blackout B O Utility in Lighting Systems Body and Accessories Bumpers 8 141 Clevis Tie Down Replacement Front Removal Procedure 1 Remove the bolt 1 and nut 3 2 Remove the clevis 2 from the mount Installation Procedure 1 Install the clevis 2 to the mount Notice Refer to Fastener Notice in Cautions and Notices Notice Clevis must move once torqued Do not over torque 2 Install the bolt 1 and nut 3 Tighten Tighten nut and bolt to 200 N m 148 Ib ft Clevis Tie Down Replacement Front Utility Removal Procedure 1 Remove the bolt 3 and nut 1 2 Remove the clevis 2 from the mount ESS A BL AL 2 2 M 2004 LSSV Truck 8 142 Bumpers Body and Accessories CS aL P mm 2004 LSSV Truck Installation Procedure 1 Install the clevis 2 to the mount Notice Refer to Fastener Notice in Cautions and Notices Notice Clevis must move once torqued Do not over torque 2 Install the bolt 3 and nut 1 Tighten Tighten nut and bolt to 200 N m 148 Ib ft Clevis Tie Down Support Replacement Front Utility Removal Procedure 1 Remove engine shield if equipped 2 Remove the front clevis tie downs Refer to Clevis
146. panel for voltmeter Inline Harness Connector End Views C305M 2 Cavities Under I P for C TSY interrupt Inline Harness Connector End Views C306M 1 Cavity Under for backup lamps Inline Harness Connector End Views C307M 7 Cavities Under I P Dimming Relay Inline Harness Connector End Views C308M 2 Cavities Under UP for blackout switch Inline Harness Connector End Views C900M 3 Cavities Rear bumper for trailer connector Power and Grounding Component Views Inline Harness Connector End Views C901M 3 Cavities Rear bumper for trailer connector Power and Grounding Component Views Inline Harness Connector End Views C902M 2 Cavities C903M 2 Cavities C904M 2 Cavities Rear bumper for right blackout B O marker Rear bumper for left blackout B O marker Right rear behind taillamp Power and Grounding Component Views Power and Grounding Component Views Inline Harness Connector End Views Inline Harness Connector End Views Inline Harness Connector End Views C905M 4 Cavities Rear of vehicle for trailer connector Inline Harness Connector End Views C906M 4 Cavities Rear of vehicle for trailer connector Inline Harness Connector End Views C907M 4 Cavities Rear of vehicle for trailer connector Inline Harness Connector End Views C908M 4 Cavities Rear of vehicle for trailer connector
147. port system 6 Remove the 6 side frame rail to bracket bolts 7 Remove the 4 bumper reinforcement bolts 8 Using the aid of an assistant remove the rear bumper from the vehicle 9 Remove the trailer wiring harness from the rear bumper Refer to Blackout B O and Trailer Harness Replacement Rear in Wiring Systems 10 Remove the blackout B O marker lamps Refer to Marker Lamp Replacement Rear in Lighting Systems 11 Remove the military trailer connector Refer to Military Trailer Connector Replacement in Wiring Systems 12 Remove the commercial trailer connector Refer to Commercial Trailer Connector Replacement in Wiring Systems 13 Remove the clevis tie down Refer to Clevis Tie Down Replacement Rear Military Bumper Installation Procedure 1 Install the clevis tie down 2 Refer to Clevis Tie Down Replacement Rear Military Bumper 2 Install the blackout B O marker lamps Refer to Marker Lamp Replacement Rear in Lighting Systems 3 Install the military trailer connector Refer to Military Trailer Connector Replacement in Wiring Systems 4 Install the commercial trailer connector Refer to Commercial Trailer Connector Replacement in Wiring Systems 5 Install the trailer wiring harness Refer to Blackout B O and Trailer Harness Replacement Rear in Wiring Systems 6 Support the rear bumper using an approved support system 7 Using the aid of an assistant position the rear bu
148. pper dome lamp The lamp is ground on the CHMSL circuit Topper Dome Lamp Description The topper dome lamp is controlled by two 3 way switches and a lamp mounted switch The interior switch is mounted in the accessory panel and the other is mounted on the left rear of the pickup bed The switch mounted on the lamp must be in the ON position for the two 3 way switches to operate the lamp Voltmeter Lamp Circuit Description When the headlamp switch is in the ON position voltage is applied through the BRN 9 wire and is grounded through the BLK 150 wire Voltmeter Lamp Description The voltmeter lamp provides illumination to the voltmeter mounted in the accessory panel Body and Accessories Lighting Systems 8 115 Function Tables Exterior Lights Exterior Lamp or Device Service Switch Blackout B O Drive Light Switch Headlamps and Taillamps ON OFF Fog Lamps ON OFF Parking Lamps ON OFF Front Rear Side Marker Lamps ON OFF Marker Lamps Roof Fender and ON OFF Endgate Stoplamps ON OFF Back up Lamps ON OFF License Plate Lamp ON OFF Front Rear Turn Signals ON OFF Hazard Warning Lamps ON ON OFF Cargo Lamp ON OFF Horn ON OFF Front Rear Blackout B O Marker B O ON OFF Lamps Blackout B O Stoplamps B O ON OFF Blackout B O Drive Lamp Headlamp B O ON Interior Lights Interior Lamp or Device Service Switch Blackout B O Drive Light Switch Instrument Panel Switch Illum
149. pply Voltage 2004 LSSV Truck S ody and Accessories Inline Harness Connector C306M Wiring Systems 8 35 E ql 14629 10796 e 12047682 e 12047683 e 17 F M P 150 Series pinche 1 Way M 150 Series BLK BLK Wire Circuit Wire Circuit Color No Function Pin Color No Function A GRN 24 Backup Lamp Supply A LT 24 Backup Lamp Supply Voltage GRY BLK Voltage 2004 LSSV Truck 8 36 Wiring Systems Inline Harness Connector C307M Body and Accessorie T 1 1 7 NE EE LE CD UD UD Ud CL 14628 14627 Connector Part t HUBS Connector Part 1206584 Information e 7 Way F M P 100 Information e 7 Way M MP 100 Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function 1 GRY 1056 Dimmer Switch 5V 1 GRY 1056 Dimmer Switch 5V Reference Voltage Reference Voltage from Dimming Relay from Dimming Relay 2 ORN BLK 2090 Dimmer Switch 2 ORN WHT 2090 Dimmer Switch Signal from Dimming Signal from Dimming Relay Relay 3 GRY BLK 2226 Dimmer Switch Low 3 GRY BLK 2226 Dimmer Switch Reference from Signal from Dimming Dimming Relay Relay Not Used 4 Not Used GRY 1056 Dimmer Switch 5V 5 GRY 1056 Dimmer Switch 5V Reference Voltage Reference Voltage from BCM from BCM 6 YEL BLK 2090 Dimmer Switch 6 YEL BLK 2090 Dimmer Switch Signal from BCM Signal from BCM
150. r poouepun xolg 0S 18 L uogount i laas ze L 1d 4901 esn4j 006 Q33 L Ayn soneuieuos 191494002 19MOd AvZ 2004 LSSV Truck Engine 6 10 Engine Electrical af Tenna al v zoio Asayeg AZL OL uonounr peeuxng Juno soneuieuos uoulM 2004 LSSV Truck Engine Engine Electrical 6 11 Component Locator Starting and Charging Component Views Voltmeter and Lamp Legend 1 Voltmeter 24V 4 Voltmeter Bracket 2 Voltmeter Connector 5 Harness Connector 3 Accessory Panel 6 Voltmeter Illumination Bulb 2004 LSSV Truck 6 12 Engine Electrical Engine Blackout B O Lamp Switches Legend 1 Accessory Panel 5 Drive Lamp Switch Connector 2 Switch Position Label 6 Blackout B O Drive Lamp Switch 3 Blackout B O Control Switch 7 Accessory Switch Openings 4 Control Switch Connector 2004 LSSV Truck Engine Engine Electrical 6 13 Power Converter 2 00 Qv Legend 1 Ground Terminal 4 Fuse Link Covers 2 12V Terminal 5 Ignition Terminal 3 24V Terminal 6 Power Converter 41204 Utility Only 2004 LSSV Truck 6 14 Engine Electrical Engine Relay Block I P Legend 1 Cavity C Blackout B O Switch C4 Connector Location 6 7 8 2 C8 Connector Location Cavity D MAP Receptacle If equipped Cavity F 24V Me
151. r connection in circuit 150 between the voltmeter relay terminal 86 and the GND terminal of the power 11 converter Is the repair complete Go to Step 15 Repair the open in circuit 150 between the voltmeter terminal B 12 and ground Is the repair complete Go to Step 15 Repair the open in circuit 901 between the voltmeter relay 13 terminal 30 and the voltmeter terminal A E Is the repair complete Go to Step 15 1 Inspect for a poor connection at the voltmeter relay 14 2 Ifthe connection is OK replace the relay Refer to Relay Replacement 24V Generator Is the replacement complete Go to Step 15 R Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 3 Voltmeter Inaccurate or Inoperative Pickup Voltmeter Inaccurate or Inoperative Pickup Step Action Yes No Schematic Reference Engine Electrical Schematics 1 Did you review the Charging System Description and Go to Description Operation Go to Step 2 and Operation 1 Turn the ignition ON with the engine OFF 2 With a DMM measure the voltage of the 24V battery 2 and compare the voltage value with the voltmeter display Go to 24V Does the voltmeter display approximately the same value as the Generator battery voltage Inoperative Go to Step 3 Test the battery voltage circuit of the voltmeter for an open for a short to ground or for a high resistance Did you find and correct the condition Go to Step 6 Go to Step 4 Test
152. r repainting to avoid marks and dirt on the new paint It is very difficult to clean up without leaving noticeable damage Grille Refinishing Procedure Note Ensure that all chrome areas have 100 coverage 1 Using a coarse refinishing material scuff the surface of the grille 2 Using etching primer prepare the surface of the grille for the finish coat 3 Repaint all exterior metal with lustreless paint Refer to Exterior and Interior Colors Chart for current paint part number Important This is not CARC paint The recommended suppler is PPG 2004 LSSV Truck Body and Accessories Frame and Underbody 8 179 Frame and Underbody Specifications Fastener Tightening Specifications Specification Application Metric English Receiver Hitch Bolts Military Hitch Utility 125 Nem 92 Ib ft Trailer Hitch Mounting Bolts Maintenance Body 117 Nem 87 Ib ft 2004 LSSV Truck 8 180 Frame and Underbody Body and Accessories BLANK 2004 LSSV Truck Body and Accessories Frame and Underbody 8 181 Repair Instructions Military Rear Receiver Hitch Replacement Utility Removal Procedure 1 Remove the pintle hitch from the receiver 2 Remove the clevis mounts Refer to Clevis Tie Down Bracket Replacement Rear Utility in Bumpers 3 Remove the bolts 3 from the bumper Remove the bolts 1 from the frame 5 Remove the receiver 2 from the vehicle gt Installation Procedure
153. r to Clevis Tie Down Replacement Front Install the front radiator grille Refer to Radiator Grille Replacement in Exterior Trim Install the radiator grille brush guard Refer to Radiator Grille Brush Guard Replacement Utility Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Slave Receptacle Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Remove the fasteners 3 securing the slave receptacle to the slave receptacle cover 2 and connect the rear connector cover 1 Remove the slave receptacle cover 2 Body and Accessories Bumpers 8 139 4 5 6 Disconnect the negative cable connections 2 Remove the rubber cover from the rear of the positive cable connection Disconnect the positive cable connection 3 Remove the slave receptacle and the gasket from the bracket Installation Procedure Notice The gasket must mount to the square back of the slave start connector assembly 1 Position the slave receptacle with the gasket onto the bracket Notice Refer to Fastener Notice in Cautions and Notices 2 3 Install the positive cable onto the connection 3 Install the negative cable onto the connection 2 Tighten Tighten positive connections to 6 Nem 53 Ib in T
154. rate as described in this supplement manual refer to one of the following manuals e 2004 C K Truck Owner s Manual e 2004 C K Truck Service Manual e 2004 Diesel Engine Owner s Manual Supplement e 2004 LSSV Owner s Manual Supplement If the concern still has not been corrected shut down the engine and notify your military maintenance unit Periodic Maintenance Inspection e Inspect the condition of the headlamps taillamps turn signals side lamps and blackout B O lamps before beginning to operate the vehicle each time Maintenance and Lubrication 0 9 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 Axle Vent Tube Filter Replacement in Front Drive Axle or Rear Axle Vent Tube Filter Replacement in Rear Drive Axle Inspect the transfer case vent tube filter for blockages every six months and more often when difficult off road conditions are encountered Replace as needed Refer to Transfer Case Vent Tube Filter Replacement Procedure in Driveline Axle 2004 LSSV Truck 0 10 Maintenance and Lubrication General Information BLANK 2004 LSSV Truck Suspension Table of Contents 3 1 Section 3 Suspension Tires and Wheels 3 3 Repair Instructions eene 3 3 Tire Hoist Shaft Extension Replacement 3 3 Description and
155. rd the axle vent pipe If replacing the hose the length of the new hose must match the length of the old hose 1 Install the filter 1 to the hoses 2004 LSSV Truck 4 4 Front Drive Axle Driveline 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 Inspection in Maintenance and Lubrication 2004 LSSV Truck Driveline Axle Rear Drive Axle 4 5 Rear Drive Axle Repair Instructions Rear Axle Vent Tube Filter Replacement Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices 1 Raise and support the vehicle 2 Install safety stands 3 Remove the filter 1 from the hoses and discard Installation Procedure Notice The filter arrow must point toward the axle vent pipe If replacing the hose the length of the new hose must match the length of the old hose 1 Install the filter 1 to the hoses 2 Remove safety stands 3 Lower the vehicle 2004 LSSV Truck 4 6 Rear Drive Axle Driveline Axle Description and Operation Rear Axle Vent Tube Filter Description Th
156. relay block harness next to the Underhood fuse block S301M In the voltage regulator harness under the UD 5304 In I P wiring harness under I P NM MES S306M In the relay block harness next to the Underhood fuse block S307M In the relay block harness next to the Underhood fuse block E S308M In the interrupt relay harness under the I P mE S309M In the interrupt relay harness under the I P M S310M In the interrupt relay harness under the I P MN E 311M In the interrupt relay harness under the I P A ES 312M In the interrupt relay harness under the I P UM en S313M In the I P harness under the I P S901M In the rear blackout B O harness at rear bumper 2004 LSSV Truck 8 16 Wiring Systems Body and Accessories Master Electrical Component List cont d Name Location Locator View Connector End View 902M In the rear blackout B O harness at rear bumper 5903 In the trailer harness at rear bumper S904M In the rear trailer harness at rear bumper e DEM S905M In the rear blackout B O harness at the rear bumper S906M In the extension lamp harness behind the left rear taillamp 5907 In the rear blackout harness the rear bumper S908M In the trailer harness at rear bumper M S909M Utility In the trailer harness at rear bumper 2004 LSSV Truck Body and Accessories Wiring Systems 8 17 Power and Groundin
157. ription Operation Go to Step 2 and Operation 1 Place the blackout service switch in blackout B O mode 2 2 Connect a test lamp at cavity C of the blackout B O switch and ground Does the test lamp illuminate Go to Step 3 Go to Step 6 1 Disconnect the blackout B O service switch connector from the switch 3 2 Connect test lamp at cavity C of the connector and ground Does the test lamp illuminate Go to Step 5 Go to Step 4 Replace the blackout B O service switch Did you complete the replacement Go to Step 9 PEE Locate and repair the short to voltage on circuit 912 ORN i Did you complete the repair Go to Step 9 mE 8 Remove the DRL interrupt relay from the relay module Are the DRLs illuminated Go to Step 8 Go to Step 7 Replace the DRL relay Did you complete the replacement Go to Step 9 m Locate and repair the short to voltage on circuit 592 LT 8 GRN BLK mu Did you complete the repair Go to Step 9 5 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 2004 LSSV Truck 8 94 Lighting Systems Body and Accessories Backup Lamps Operate in Blackout B O Mode Step Action Yes No Schematic Reference Lighting Systems Schematics 1 Did you review Blackout B O Lighting Description and Go to Description Operation Go to Step 2 and Operation 1 Place the blackout B O service switch in blackout B O mode 2 2 Connect a test lamp at cavity C of
158. rker Lamp Replacement Rear PickUp c i ceno rt rte 8 103 Marker Lamp Replacement Rear Utility sator ret 8 105 2004 LSSV Truck 4 Taillamp Bulb Replacement Maintenance Body nate ee ae eaten 8 108 Taillamp Replacement Maintenance Body etate Ale 8 107 Topper Dome Lamp Bulb Replacemert 8 103 Topper Dome Lamp Switch Replacement 8 113 Topper Dome Lamp Switch Replacement 8 112 Schematics eee areae 8 61 Specifications Fastener Tightening Specifications 8 61 Lighting Systems Component Views 8 71 Lighting Systems Connector End Views 8 83 Low Beam Headlamps Diagnosis Low Beam Headlamps Operate in Blackout 8 97 M Maintenance Owner Checks and 0 9 Periodic Maintenance Inspection 0 9 Maintenance Body Repair Maintenance Body Replacement 8 174 Marker Lamp Repair Marker Lamp Replacement Rear Pick lp ai three e 8 104 Marker Lamp Replacement Maintenance iia dise ade e acr adhac o 8 109 Repair Marker Lamp Replacement Front Blackout Pickup 8 101 Marker Lamp Replacement Front Blacko
159. rkers Yellow will illuminate for the brakes and red will illuminate for drive mode The front markers illuminate in yellow The horn 2004 LSSV Truck is inoperative while the blackout B O toggle is in the ON position All warning lamps in the I P remain functional regardless of the toggle position If the vehicle is parked for over 24 hours place the service switch in the ALL OFF position To operate the blackout B O drive light switch pull it out and up to the ON position this will activate the front blackout B O headlamp This will occur provided the service light blackout B O switch remains in the ON or down position Pulling the left blackout B O drive light switch out and down to the OFF position will turn it OFF Releasing the switch from ON or OFF will cause it to return to the center position automatically The following Exterior Interior lights function tables are for the service light blackout B O control switch and clarify under what conditions various exterior and interior lighting functions activate Additional details are found in the 2004 C K Truck Owner Manual Topper Dome Lamp Circuit Description When the ignition switch is ON voltage is supplied from the blackout B O switch to the interior toggle switch on circuit 912 ORN The voltage leaves the switch on circuit 800 BRN or 803 BRN WHT pending on the switches position The voltage on these circuits goes to the rear toggle switch then to the to
160. rns Body and Accessories Horns Inoperative cont d Step Action Yes No Repair the open or high resistance the ORN circuit 40 Did you complete the repair Go to Step 13 a is Verify the system operation Do the horns operate properly System OK Go to Step 2 Horns Operate in Blackout B O Mode Step Action Yes No Schematic Reference Horn Schematics 1 Did you review Horns Description and Operation Go to Description Go to Step 2 and Operation Connect a test lamp between terminal 86 of the horn 2 interrupt relay block and ground Does the test lamp illuminate Go to Step 4 Go to Step 3 amp Replace the horn interrupt relay Did you complete the replacement Go to Step 7 1 Disconnect the blackout B O service switch 4 2 Connect test lamp between cavity C of the blackout B O switch connector and ground Does the test lamp illuminate Go to Step 6 Go to Step 5 Replace the blackout B O service lamp switch Refer to Blackout B O Switch Replacement in Instrument Panel 5 Gages and Console Did you complete the replacement Go to Step 7 Repair the short to voltage in the ORN circuit 912 Did you complete the repair Go to Step 7 m lt Verify the system operation Do the horns operate properly System OK Go to Step 2 2004 LSSV Truck Body and Accessories Horns 8 127 Description and Operation Horn with Blackout B O Control
161. rt your vehicle by pushing or pulling it won t work and it could damage your vehicle You should always use the slave receptacle and NATO Slave Cable when performing this operation 1 Position the vehicles close enough so the slave cable can reach but be sure the vehicles are not touching each other If they are it could cause a ground connection You would not be able to start your vehicle and the bad grounding could damage the electrical systems To avoid the possibility of the vehicles rolling set the parking brake firmly on both vehicles involved in the jump start procedure Put the automatic transmission in PARK P Be sure the transfer case is not in NEUTRAL N 2 Turn OFF the ignition on both vehicles Unplug unnecessary accessories plugged into the cigarette lighter or accessory power outlets Turn OFF all lamps that aren t needed as well as radios This will avoid sparks and help save both batteries 3 Locate the slave receptacles on both vehicles 2004 LSSV Truck 6 32 Engine Electrical Engine Caution Using an open flame near a battery can cause battery gas to explode People have been hurt doing this and some have been blinded Use a flashlight if you need more light Be sure the batteries have enough water You don t need to add water to the Optima battery or batteries installed in every vehicle But if a battery has filler caps be sure the right amount of fluid is there If it is low add water to take care
162. s 1 through the bracket and bumper into the nuts Connect the electrical connector Install the license plate onto the bracket Topper Dome Lamp Switch Replacement Rear Removal Procedure Remove the left rear tail turn signal lamp Refer to Tail Turn Signal Lamp Replacement except step side in Lighting Systems in 2004 C K Truck Service Manual Remove the connector 2 from the switch From inside the cargo area remove the nut from the switch Remove the switch 1 from the vehicle Installation Procedure RLO DU Install the switch 1 into the vehicle From inside the cargo area install the nut onto the switch Install the connector 2 onto the switch Install the left rear tail turn signal lamp Refer to Tail Turn Signal Lamp Replacement except step side in Lighting Systems in the 2004 C K Truck Service Manual Body and Accessories Topper Dome Lamp Switch Replacement Front Removal Procedure Caution Refer to Battery Disconnect Caution in Caution and Notices 1 2 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Remove the accessory panel Refer to Accessory Panel Replacement in Instrument Panel Gages and Console Remove the nut 2 and washer 3 from the switch Remove the switch 4 from the panel 1 Installation Procedure Install the switch 4 into the panel 1 Install the washer 3 and nut 2 and tighten Install the
163. s 2 18 Ib in Taillamp Bracket to Bumper Nuts 27 20 Ib ft Schematic and Routing Diagrams 2004 LSSV Truck Body and Accessories Systems 8 62 Lightin swayshs r 3 u AN U9IIMSI A 4 uonnquisiQ LHM dos ___ L06 NVL Y LHM 206 NH9 WEOES 80 16 L ZLJLHM CL6 NHO L WOES WOES a LL6 L LHM 6 ANd L06 NYL LHM L 06 8 18 U9IIMS due Aejay YOUMS e uq jnoyoelg noyoejg LHM L06 L Ov NYO L6 LHM L LOL 88 89 O 5 50 ye i asni Aejay 4 4 01 U09 14617 0 8 1noxo elg 2004 LSSV Truck Lighting Systems 8 63 Body and Accessories jenueyy 22199 JONIL v00c ut uiejs s uyl due Jaddoy YMS 5 9 660 perm a ia NH8 0L IHAVNMS OL 208 c No AdHWNSHOT dnyxoig ddo 2004 LSSV Truck Body and Accessories Systems 8 64 Lightin jenueyy yond M O YOO 941 0 uononpoJg jenueyy M O v00c 91 1943Y euiBu3 AvZ suiejs S soneuieuos ur eld uonnqujsig punoJo esueor
164. s in Lighting Systems Blackout B O Stop Marker Lamp RR Blackout B O Drive Lamp Switch Headlamp In the right side of the rear bumper In the accessory panel on the center lower next to the 24V meter Lighting Systems Component Views in Lighting Systems Engine Electrical Component Views in Engine Electrical Lighting Systems Connector End Views in Lighting Systems Lighting Systems Connector End Views in Lighting Systems Battery 12V Outside of frame rail under passenger seat Diesel Only Battery 12V At the right rear engine compartment Battery 24V At the left front of the engine compartment Circuit Breaker 12V In the engine compartment on the left fender brace Utility Engine Electrical Component Views in Engine Electrical Circuit Breaker 24V In the engine compartment on the left fender brace Utility Engine Electrical Component Views in Engine Electrical CTSY 1 and 2 Relay Inline on the interrupt harness under the VP 2004 LSSV Truck Body and Accessories Wiring Systems 8 13 Master Electrical Component List cont d Name Location Locator View Connector End View DRL Interrupt Relay Interrupt relay block RH engine compartment Lighting Systems Component Views in Lighting Systems Generator 24V The right front of engine Generator Relay 24V On the cover of the Underhood
165. seating for up to 4 troops on each side Each bench is anchored by 3 sets of fasteners to each box rail The seats can be folded up using tether pins to afford more cargo space They are equipped with a safety strap which should be hooked across the rear end of the box when occupied Refer to the 2004 LSSV Owner s Manual Supplement for further details Seat Covers Seat covers are installed on the interior seats to protect the vehicle s interior and are green or tan in color They allow full function of the seat controls and seat belts 2004 LSSV Truck Body and Accessories Interior Trim 8 159 Interior Trim Specifications Fastener Tightening Specifications Specification Application Metric English Floor Mount Gun Rack Bolts 8 70 Ib in Floor Mount Gun Rack Bolts Front Utility 55 Nem 41 Ib ft Lower Gun Rack Bolts 8 70 Ib in Upper Gun Rack Bolts 8 70 Ib in 2004 LSSV Truck 8 160 Interior Trim Body and Accessories Repair Instructions Government Vehicle Data Plate Replacement Removal Procedure 1 Drill out the 4 rivets 3 2 Remove the data plate 2 Installation Procedure 1 Install the plate 2 to the original holes 2 Install the new rivets 3 Shipping Data Plate Replacement Removal Procedure 1 Drill out the 4 rivets 3 2 Remove the data plate 1 2004 LSSV Truck Body and Accessories Interior Trim 8 161 Installation Procedure 1
166. t in Bumpers Install the positive slave receptacle cable in the same routing location as removed Connect the positive slave receptacle cable connector 3 to the 24V battery connection Install the negative slave receptacle cable in the same routing location as removed Connect the negative slave receptacle connector 1 to the cable ground connection Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Body and Accessories Wiring Systems 8 59 Description and Operation Wiring Description Several changes offered by the military options require new wiring configurations Auxiliary wiring attaches to the original wiring providing power to the following items e Blackout B O Lighting e 24V System e Power Converter e Circuit Breakers and Relays e Slave Receptacle e Winch Prep Wiring All auxiliary harnesses are outlined in schematics Several are described in repair procedures in this manual Access to fuses can be found under the dash and under the hood or inline with the circuit 2004 LSSV Truck 8 60 Wiring Systems Body and Accessories BLANK 2004 LSSV Truck Body and Accessories Lighting Systems 8 61 Lighting Systems Specifications Fastener Tightening Specifications Specification Application Metric English Blackout B O Headlamp Stud Nut 10 Nem 89 Ib in Front Blackout B O Marker Lamp Nuts 2 18 Ib in Rear Blackout B O Lamp Nut
167. t the blackout B O service switch connector from the switch 3 2 Connect a test lamp at cavity C of the connector and ground Does the test lamp illuminate Go to Step 5 Go to Step 4 Replace the blackout B O service switch Did you complete the replacement Go to Step 9 m 5 Locate and repair the short to voltage on circuit 912 ORN Did you complete the repair Go to Step 9 m Remove the backup lamp interrupt relay from the relay 6 module Are the backup lamps illuminated Go to Step 8 Go to Step 7 Replace the backup interrupt relay Did you complete the replacement Go to Step 9 BE Locate and repair the short to voltage on circuit 1970 8 PNK WHT Did you complete the repair Go to Step 9 Operate the system in order to verify the repair Did you correct condition System OK Go to Step 2 Body and Accessories Lighting Systems 8 99 Repair Instructions Headlamp Replacement Blackout B O Pickup Removal Procedure 1 Remove the nut and washer 3 from the lamp stud at the base of the mounting bracket 2 Remove the ground lead 4 by sliding it off the stud 3 Disconnect the auxiliary wiring harness connector 2 from the headlamp 4 Remove the blackout B O lamp assembly 1 from the mounting bracket Installation Procedure 1 Install the blackout B O lamp assembly 1 to the mounting bracket 2 Connect the auxiliary wiring harness connector 2 3 Install the ground lead 4 by
168. tage BLK 1750 Ground BLK 1750 Ground D DK GRN 1619 Right Stop Turn D GRN 1619 Right Stop Turn Supply Voltage Supply Voltage 2004 LSSV Truck 8 42 Wiring Systems Inline Harness Connector C909M Body and Accessorie 10561 10565 e 12015791 e 12010996 E e 1 Way F Weather Pack eer s 1 Way M Weather Pack BLK BLK Wire Circuit Wire Circuit Pin Color No Function Pin Color No Function A RED 87 Power to Trailer A RED 802 Power to Trailer Relays Relays Inline Harness Connector C910M 10561 10565 e 12015791 e 12010996 1 Way F Weather Pack reed d n 1 Way M Weather Pack BLK BLK Wire Circuit 5 Wire Circuit Pin Color No Function Pin Color No Function A BRN 9 Park Lamps Supply A BRN WHT 2609 Park Lamps Supply Voltage Voltage 2004 LSSV Truck S ody and Accessories Wiring Systems 8 4 Inline Harness Connector C911M AS Num 5669 DOQQ A D A 10583 10584 e 12020832 e 12020830 B e 4 Way F Weather Pack Somerin n n e 4 Way M Weather Pack TWR BLK SHD BLK Wire Circuit Wire Circuit Color No Function Pin Color No Function A BRN 2109 Trailer Park Lamp A BRN 9 Trailer Lamp Supply Supply Voltage Voltage B YEL 1608 Left Stop Turn Supply YEL 18 Left Stop Turn Supply Voltage Voltage
169. ter Supply Voltage Relay Block I P ee ERN 2 3 C5 Connector Location 4 Cavity E 24V Meter Ground 2004 LSSV Truck Engine Engine Electrical 6 15 12V and 24V Circuit Breakers Legend 1 50 amp 24V Circuit Breaker 4 Bolt 2 Circuit Breaker Bracket 5 Screw 3 120 amp 12V Circuit Breaker 2004 LSSV Truck 6 16 Engine Electrical Engine Underhood Wiring Legend 1 Interrupt Relays 5 To Rear Extension Harness 2 To Front Blackout B O Lamps 6 Ground Stud 3 To Ground Stud 7 Blackout B O Panel Harness 4 To Engine Harness 2004 LSSV Truck Engine Engine Electrical 6 17 24V Slave Receptacle Assembly Legend 1 Battery Negative Ground Black 3 Slave Receptacle Cover 2 Battery Positive Ground Red 4 Slave Receptacle 2004 LSSV Truck 6 18 Engine Electrical Engine Bulkhead Junction Block Legend 1 Junction Block 5 Negative Winch Prep Cable Rear 2 Jumper Plate 6 Battery Negative Cable 7 Battery Positive Cable 8 Positive Winch Prep Cable Rear 2 3 Ground Connection 4 Mounting Bracket 2004 LSSV Truck Engine Engine Electrical 6 19 Winch Cable and Starter Cable Junction Block Legend 1 Battery Positive Cable 4 Junction Block Post Nut 2 Junction Block 5 Positive Winch Prep Cable Front 3 Generator Output Cable 6 Junction Block Post 2004 LSSV Truck 6 20 Engine Electrical Starting and C
170. the tire hoist is damaged it must be replaced Refer to Tire Hoist and Shaft Replacement in Tires and Wheels in the 2004 C K Truck Service Manual 2004 LSSV Truck Driveline Axle Table of Contents 4 1 Section 4 Driveline Axle Front Drive 4 3 Transfer CaS uses ec cepe eaiuiaa Goa E sz s 4 7 Repair Instructions eee 4 3 Repair Instructions eere 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 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 5 Rear Axle Vent Tube Filter Replacement 4 5 Description and Operation 4 6 Rear Axle Vent Tube Filter Description 4 6 2004 LSSV Truck 4 2 Table of Contents Driveline Axle BLANK 2004 LSSV Truck Driveline Axle Front Drive Axle 4 3 Front Drive Axle Repair Instructions Front Axle Vent Tube Filter Replacement Removal Procedure 1 Remove the filter 1 from the hoses and discard Installation Procedure Notice The filter arrow must point towa
171. ty 75 lb ft Slave Receptacle Harness Connections 53 Ib in Slave Receptacle Mounting Bolts 8 Nem 71 Ib in 2004 LSSV Truck 8 134 lt Body and Accessories 2004 LSSV Truck Repair Instructions Bumper Replacement Front Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical 2 Remove the blackout B O headlamp Refer to Headlamp Replacement Blackout B O Pickup in Lighting Systems 3 Remove the slave receptacle Refer to Slave Receptacle Replacement 4 Remove the blackout B O marker lamp Refer to Marker Lamp Replacement Front Blackout B O Pickup in Lighting Systems 5 Remove the 3 bolts and the 3 clamps securing the slave receptacle harness and the blackout B O harness to the bumper assembly 6 Remove the winch connector Refer to Winch Connector Harness Replacement Front in Wiring Systems 7 Support the bumper assembly using an approved support system 8 Remove the 2 bolts from the upper bumper supports 9 Remove the 4 bolts from the lower supports Body and Accessories Bumpers 8 135 10 Remove the 2 bolts and the 2 nuts from the center bumper supports 11 Using the aid of an assistant remove the bumper assembly from the vehicle 12 Remove the clevis tie downs Refer to Clevis Tie Down Replacement Front
172. uminate Go to Step 4 Go to Step 3 Replace blackout B O drive relay Did you complete the replacement Go to Step 5 Replace blackout B O service switch Refer to Blackout B O Switch Replacement in Instrument Panel Gages and 4 Console Did you complete the replacement Go to Step 5 5 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 Backup Lamps Inoperative Step Action Yes No Schematic Reference Lighting Systems Schematics 1 Did you review Blackout B O Lighting Description and Go to Description Operation Go to Step 2 and Operation 2 Is only one backup lamp inoperative Go to Step 3 Go to Step 4 2004 LSSV Truck Body and Accessories Lighting Systems 8 89 Backup Lamps Inoperative cont d Step Action Test the backup lamp supply voltage circuit of the inoperative bulb for high resistance an open or a short to ground Did you find and correct the condition Yes Go to Step 17 No Go to Step 5 1 Inspect the condition of the backup lamp fuses 2 If the fuse is open locate and repair the source of the overload and replace fuse Did you find and correct the condition Go to Step 17 Go to Step 6 Test the ground circuit of the inoperative bulb for high resistance or an open Did you find and correct the condition Go to Step 17 Go to Step 13 Connect a test la
173. unction block nuts to 9 Nem 80 Ib in Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Slave Receptacle Harness Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 2 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Trace the negative slave receptacle cable 1 to the cable ground connection Disconnect the negative slave receptacle ground cable from the ground connection Trace the positive slave receptacle cable 3 to the 24V battery connection Disconnect the positive slave receptacle cable 3 from the 24V battery connection Disconnect the slave receptacle connectors from the slave receptacle Refer to Slave Receptacle Replacement in Bumpers Remove the fasteners from the clamps securing the slave receptacle harness and the blackout B O harness Remove the slave receptacle harness from the bumper assembly 2004 LSSV Truck 8 58 Wiring Systems Body and Accessories 2004 LSSV Truck Installation Procedure Notice Verify all connections are clean prior to installation Position the slave receptacle harness onto the bumper assembly Install the 3 clamps and the fasteners onto the slave receptacle harness and the blackout B O harness Connect the slave receptacle connectors to the slave receptacle Refer to Slave Receptacle Replacemen
174. underhood junction block 4 Secure the wiring harness to the clip 2 2004 LSSV Truck 6 36 Engine Electrical Engine 2004 LSSV Truck 24V Generator Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure 2 Remove the drive belt Refer to Drive Belt Replacement in Engine Mechanical 6 6L in the 2004 C K Truck Service Manual 3 Disconnect the generator electrical connector 4 Remove the cable from the output stud 5 Remove the generator bolts 6 Remove the generator from the vehicle Installation Procedure 1 Install the cable onto the output stud of the generator Notice Refer to Fastener Notice in Cautions and Notices 2 Install the nut onto the output stud Tighten Tighten output stud to 9 N m 80 Ib in Engine Electrical 6 37 Engine 3 Install the generator into the mounting bracket 4 Install the generator bolts Tighten Tighten generator bolts to 50 N m 37 Ib ft 5 Connect the generator electrical connector 6 Install the drive belt Refer to Drive Belt Replacement in Engine Mechanical 6 6L in the 2004 C K Truck Service Manual 7 Connect the battery cables Refer to Battery Cable Disconnect Connect Procedure Battery Cable Disconnect Connect Procedure Removal Procedure 1 2 3 Turn OFF all the lamps and accessories
175. ut Utility 8 102 Marker Lamp Replacement Rear Utility 22 5 2 2 aret eed 8 105 Master Electrical Component List 8 12 Military Equipment 0 5 Military Rear Receiver Hitch Replacement ee tt 8 181 Military Trailer Connector Replacement 8 50 Military Trailer Connector Replacement Factory BUMPO 8 49 Paint Coatings Exterior and Interior Colors 8 177 Repair Exterior Painting 1 8 178 Grille Refinishing esses 8 178 Park Lamps Park Lamps Operate in Blackout B O Mode 8 94 Pintle Hook Repair Pintle Hook Replacement 8 148 Power and Grounding Component VIEWS sese ee ee eee ee 8 17 2004 LSSV Truck Power Converter Repair Power Converter Replacement Utility 6 41 R Radiator Grille Repair Radiator Grille 8 130 Radiator Grille Brush Guard Replacement 8 140 Radiator Grille Brush Guard Replacement OY ave tect ts 8 140 Rear Drive Axle Description Rear Axle Vent Tube 4 6 Repair Rear Axle Vent Tube Filter Replacement 4 5 Rear Mud Flap Repair Rear Mud Flap Replacement 8 130
176. ution in Cautions and Notices 1 Raise and support the vehicle Remove the brace bolt 3 Remove the plastic retainer 1 Remove the screws 2 Remove the mud flap 4 from the vehicle Qu d 0o Installation Procedure 1 Install the mud flap 4 to the vehicle 2 Install the plastic retainer 1 Notice Refer to Fastener Notice in Cautions and Notices 3 Install the brace bolt 3 Tighten Tighten the brace bolt to 25 N m 18 Ib ft 4 Install the screws 2 Tighten Tighten the screws to 4 Nem 35 Ib in 5 Remove the supports and lower the vehicle Radiator Grille Replacement Removal Procedure 1 Remove the radiator grille brush guard Refer to Radiator Grille Brush Guard Replacement Utility in Bumpers 2 Remove the upper air baffle Body and Accessories Exterior Trim 8 131 3 Release the fasteners holding the radiator grille to the radiator support 4 Remove the radiator grille Installation Procedure 1 Paint the new radiator grille Refer to Paint Codes in Paint Coatings 2 Install the radiator grille and bolts 3 Install the upper grille baffle 4 Install the radiator grille brush guard Refer to Radiator Grille Brush Guard Replacement Utility in Bumpers 2004 LSSV Truck 8 132 Exterior Trim Body and Accessories Description and Operation Exterior Trim Description Mud Flaps The military vehicles may be equipped with mud flaps at the front of the rear wheel openings to pr
177. ve the bolts 1 securing the cap to the bed rails 3 With the aid of an assistant remove the top from the vehicle 4 Remove the old sealer tape from the bed rails Installation Procedure 1 Install the new sealer tape to the bed rails 2 With the aid of an assistant place the top on the bed rails Notice Refer to Fastener Notice in Cautions and Notices 3 Install the bolts 1 and tighten Tighten Tighten bolts to 68 N m 50 Ib ft 4 Connect the electrical connection for light Cargo Cover Side Rail and Hinge Replacement Removal Procedure 1 Remove the cargo cover the top bows and side struts Refer to Cargo Cover Top Bows Replacement and Cargo Cover Strut Replacement 2 Remove the troop seats Refer to Seat Replacement Troop in Seats Body and Accessories 3 Remove the 4 bolts and nuts holding the 2 rail adapter plates to the side rail Remove the 2 bolts and nuts holding the bow hinge bracket Remove the side rail and adapter rail Remove the bow hinge bracket Remove the side rail Remove the side rail adapter Drill out the 4 existing rivnuts if damaged from the box rail Installation Procedure 1 2 Apply 2 sided foam tape to the underside of the rails and to the edges of the mounting holes Install rivnuts to the existing holes if damaged using a rivnut installer Body Rear End 8 16 2004 LSSV Truck 9 8 170 Body Rear End Body and Accessories
178. ver and troop seating for up to eight or a hard cap with opening windows A specially upgraded electrical system can handle 24V communications equipment and charging of the 24V battery Cargo Carrier Base General Information 0 3 Cargo Troop Carrier Base Cargo Carrier Crew Cab Cargo Troop Carrier Crew Cab 2004 LSSV Truck 0 4 General Information General Information Utility Vehicle Information The utility vehicle is equipped with a 5 3L gasoline engine with a 4 speed 4L60E automatic transmission and a 2 speed transfer case Payload capacity is 1 532 lbs 696 kg but varies with equipment Utility 2004 LSSV Truck General Information General Information 0 5 Military Equipment Options 2004 Light Service Support Vehicle LSSV Specifications Options Your vehicle may be equipped with any combination of the following options Description Blackout B O Lighting Slave Start Rear Clevis Tie Downs Pintle Hook Trailer Light Connection Gun Rack Transfer Case Differential Vent Filters Government Data Plate Cargo Area Troop Seats Cargo Cover Soft Top Combination Front or Rear Mounted Winch Prep Cargo Locking Side Rear Access Fiberglass Top Pioneer Tool Kit Factory Rear Receiver Hitch Heavy Duty Front Bumper with Brush Guard and Clevis Tie Downs Heavy Duty Rear Bumper with Clevis Tie Downs and Receiver Hitch Sliding Rear Window 12V 24V
179. y Cable Disconnect Connect Procedure in Engine Electrical 2004 LSSV Truck 8 56 Wiring Systems Body and Accessories 2004 LSSV Truck Winch Connector Harness Replacement Rear Removal Procedure Caution Refer to Battery Disconnect Caution in Caution and Notices Disconnect the battery cables Refer to Battery Cable Disconnect Connect Procedure in Engine Electrical Remove the negative cable 3 from the junction block 2 Remove the positive cable 1 from the junction block 2 Remove the wiring harness straps securing the cable Note cable routing for installation Remove the clamp bolt 1 and clamp 4 from cable Remove the bolt 2 securing cable connector to the bracket Remove the cable 3 from the vehicle Installation Procedure 1 Install the cable 3 onto the vehicle in the same location as removed Notice Refer to Fastener Notice in Cautions and Notices 2 Install the connector onto the bracket and secure with bolt 2 Tighten Tighten the connector bolt to 5 8 Nem 44 71 Ib in Install the clamp 4 and secure with bolt 1 Tighten Tighten clamp bolt to 18 29 Nem 13 21 Ib ft Working from the rear to the front of the vehicle install the wiring harness straps 5 Body and Accessories Wiring Systems 8 57 5 6 Install the positive cable 1 to the junction block 2 Install the negative cable 3 to the junction block 2 Tighten Tighten j

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