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2001/02 general motors lssv military vehicles service manual

1. Does the test lamp illuminate Go to Step 3 Go to Step 4 Replace blackout service lamp switch Did you complete the replacement Go to Step 5 ES Repair short to power or inoperable blackout control relay Did you find and correct the condition Go to Step 5 BE 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 service lamp switch into the blackout mode 2 2 Connecta test lamp from cavity 85 at the blackout lighting control relay and ground Does the test lamp illuminate Go to Step 4 Go to Step 3 Replace blackout control relay Did you complete the replacement Go to Step 5 VES Replace blackout service lamp switch Did you complete the replacement Go to Step 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 Test the backup lamp supply voltage c
2. 8 100 Front Bumper Replacement Pickup Models 8 101 Radiator Grille Brush Guard Replacement 8 103 Clevis Tie Down Replacement Front 8 103 Clevis Tie Down Support Replacement Front Pickup 8 104 Clevis Tie Down Support Replacement Front 2 2 22 8 105 Bumper Replacement Rear Factory Hitch 8 106 Bumper Replacement Rear Military Hitch 8 109 Clevis Tie Down Support Replacement Rear Factory Hitch Pickup Models 8 112 Clevis Tie Down Bracket Replacement Rear Utility Extended Cab 8 112 Clevis Tie Down Bracket Replacement Rear 8 113 Pintle Hook 8 114 Clevis Tie Down Replacement 8 114 Description and Operation 8 116 8 116 Body Front e 8 117 Specifications nee 8 117 Repair Instructions 8 118 Slave Connector Replacement 8 118 Winch Mount Replacement Pickup Models 8 118 Winch Replacement Pickup Models 8 119 Description and Operation 8 121 Body Front End Description
3. 8 106 Clevis Tie Down Bracket Replacement Rear 8 113 Clevis Tie Down Bracket Replacement Rear Utility Extended 8 112 Clevis Tie Down Replacement Front 8 103 Clevis Tie Down Replacement Rear 8 114 Clevis Tie Down Support Replacement Front Pickup Models 8 104 Clevis Tie Down Support Replacement Front Utility esses 8 105 Clevis Tie Down Support Replacement Rear Factory Hitch Pickup Models 8 112 Front Bumper Replacement Pickup 8 101 Front Bumper Replacement 8 100 Pintle Hook 8 114 Radiator Grille Brush Guard Replacement 8 103 Specifications Fastener Tightening Specifications 8 99 Repair Cargo Cover Front End Rail Replacement 8 153 Cargo Cover Rear End Rail Replacement 8 154 Cargo Cover Replacement 8 157 2001 02 LSSV Truck Cargo Cover Side Rail and Hinge 8 151 Cargo Cover Stowage Replacement 8 159 Cargo Cover Strut Replacement
4. 8 122 Shock Absorber Description Front Shock Absorber 3 6 Rear Shock Absorber Description 3 9 Repair Shock Absorber Replacement gone T 3 4 2001 02 LSSV Truck INDEX een died atte ee edt 3 8 Slave Connector Replacement 8 118 Special Tools Wheel Drive Shafts 4 9 Specifications Fastener Tightening Body Front End een 8 117 Body Rear nnns 8 150 ou eie RR ed 8 99 Engine 6 3 Exterior aes 8 95 Frame and Underbody 8 162 Front 3 3 Instrument Panel Gages and Console 8 84 Interior 24 4 8 125 8 40 Rear 3 7 eni na 8 122 flo e 8 3 Starting and Charging Component 6 9 Connector End Views 6 22 Description Starting and Charging System Description and 6 42 Stoplamps Diagnosis Stoplamps
5. 26 9 Buueeis 2 Aejay sdwe jdnueju olpey 2001 02 LSSV Truck 8 54 Lighting Systems Body and Accessories Component Locator Lighting Systems Component Views Trailer Wiring Harness Legend 1 Bumper 4 Trailer Connector 2 C197 5 Trailer Connector Cover 3 C993 2001 02 LSSV Truck Body and Accessories Lighting Systems 8 55 Trailer Wiring Harness Factory Receiver Legend 1 Rear Bumper 4 Trailer Connector 2 Factory Receiver 5 Connector Cover 3 C917 6 C993 2001 02 LSSV Truck 8 56 Lighting Systems Body and Accessories Rear Lamp Harness Legend 1 C992 6 C917 2 Auxiliary Rear Lamp Extension Harness 7 C993 3 Rear Lamp Extension Harness 8 To B O Marker Lamp LH 4 Taillamp Connector 9 Ground 5 To B O Marker Lamp RH 2001 02 LSSV Truck Body and Accessories Lighting Systems 8 57 Auxiliary Rear Lamp Harness Pickup Shown Utility Similar D r Legend 1 C992 3 C133 2 Auxiliary Rear Lamp Harness 2001 02 LSSV Truck 8 58 Lighting Systems Body and Accessories Forward Blackout B O Lamp Harness Legend 1 C192 4 To B O Headlamp 2 Forward Lamp Harness 5 To B O Marker Lamp LF 3 6113 6 To B O Marker Lamp RF 2001 02 LSSV Truck Body and Accessories Lighting Systems 8 59 Rear Blackout B O Lamps
6. 6 42 Repair Instructions eere 6 31 Starting and Charging System Description Voltage Regulator 6 31 and Circuit 6 42 2001 02 LSSV Truck 6 2 Table of Contents Engine BLANK 2001 02 LSSV Truck Engine Engine Electrical 6 3 Engine Electrical Specifications Fastener Tightening Specifications Specification Application Metric English Battery Booster Slave Junction Block Flange Nuts 14 10 Ib ft Battery Cable Connections 17 N m 13 Ib ft Battery Retainer Bolt 25 18 Ib ft Circuit Breaker Bracket to Support Brace 4 6 3 4 5 Ib ft Converter Fuse Retaining Nuts 12 110 Ib in Converter Stud Jam Nuts 12 110 Ib in Converter Wiring Terminal Nuts 12 110 Ib in Schematic and Routing Diagrams 2001 02 LSSV Truck 6 4 Engine Electrical 2 9 ost 091 ya 091 X18 8 1915008 JexyeaJg sarg i Joyesqueg 228 i a Q348 0388 4 05 9018 uonounr suiejs g uonnqussiq J 32019 uonounr 1 L 959 61 2001 02 LS
7. Jejsoog Jezienb3 eoueiueAuo _ ___ Aegi 4 uonnquisig 2001 02 LSSV Truck 8 9 irin Body and Accessories HM S uonnquisiq aost 8 0 ost 78 8 0 809 18 8 0 VOSL 18 8 0 4169 5 90S 8 0 4169 idu 1 2 Joe __ 4 soneuieu s uonnquisiq 2001 02 LSSV Truck 8 10 Wiring Body and Accessories Component Locator Power and Grounding Components Name Location Locator View Connector End View Battery Booster In the grille near the RH headlamp Engine Electrical Connector Component Views in Engine Electrical Battery LH At the LF engine compartment Wiring Component Wiring Connector End Views in Wiring Systems Views in Wiring Systems Blackout Control Relay Inline auxiliary IP harness Lighting Component Views in Lighting Systems Lighting Connector End Views in Lighting Systems Blackout Headlamp At the LH of the grille Lighting Component Views in Lighting Systems Lighting Connector End Views in Lighting Systems Blackout Lighting Control Relay On the auxiliary IP
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10. 3 10 Description and Operation 3 6 Repair Instructions 3 10 Front Shock Absorber Description 3 6 Tire Hoist Shaft Extension Replacement 3 10 Rear Suspension 3 7 Description and Operation 3 11 Specifications ciconia eint a c nn 3 7 Tires and Wheels s 3 11 Repair 2 3 8 2001 02 LSSV Truck 3 2 Table of Contents Suspension BLANK 2001 02 LSSV Truck Suspension Front Suspension 3 3 Front Suspension Specifications Fastener Tightening Specifications Specification Application Metric English Shock Absorber Bolt 80 N m 59 Ib ft Shock Absorber Tennon Nut 20 N m 15 Ib ft 2001 02 LSSV Truck 3 4 Front Suspension Suspension 2001 02 LSSV Truck Repair Instructions Shock Absorber Replacement Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices Notice The front shock absorbers of the vehicle are multifunctional In addition to contributing to a smooth ride they also provide the only stop to the front suspension when fully extended Therefore when servicing the shock absorber service replacement shock absorbers must be equivalent to original shock absorbers in both extended length and strength Use of shocks not com
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12. 2 Install bolts in the mount and tighten Tighten Tighten bolts to 8 6 Ib ft 24 Voltmeter Relay Replacement Pickup Models 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 cables of the left battery 2 Remove the cover 1 from the power converter 2 3 Remove voltmeter relay 1 from connector 2 Interior Trim 8 13 2001 02 LSSV Truck 3 Body and Accessories 8 134 Interior Trim Installation Procedure 1 Install voltmeter relay 1 into connector 2 i gt e x 44 ol 2 Install the cover 1 from the power converter 2 Notice Refer to Fastener Notice in Cautions and Notices 3 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 Nem 13 Ib ft 24 Voltmeter Relay Replacement Tahoe 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 1 from the connector 3 2001 02 LSSV Truck Body and Accessories Interior Trim 8 135 Installation Procedure 1 Install the relay 1 into the connector 3 2 Install the
13. 24V Battery Booster and Starter Cable Junction Block Legend 1 Positive Batter Cable 4 Junction Block Post Nut 2 Junction Block 5 Positive Winch Cable Permanent Mount 3 Alternator Output Cable 6 Junction Block Post 2001 02 LSSV Truck Body and Accessories Wiring 8 23 Junction Block IP Legend 1 Cavity A 5 C 9 Connector Location 2 Cavity F 6 To Underhood Relay Harness 3 Cavity E 7 C 4 Connector Location 4 Junction Block IP 2001 02 LSSV Truck 8 24 Wirin Body and Accessories 24 Battery Booster Connector Legend 1 Battery Positive Ground RED 3 Battery Negative Ground BLK 2 Booster Connector Assembly 2001 02 LSSV Truck B ody and Accessories Connector End Views Power and Grounding Connector End Views Inline Harness Connector C133 Wiring 8 25 Inline Harness Connector C134 t tu M pues B A 10573 Connector Part e 12010973 Information 2 Way F Weather SHD BLK Wire Circuit No Function Pin Color A TAN WHT 901 B O Head Lamp B BRN 900A B O Marker Lamps WHT Connector Part e 12089040 Information e 2 Way M Weather Pack TWR MED GRY Wire Circuit No Function Pin Color A 900B B O Marker Lamps B DK GRN 902 B O Stop Lamps WHT Inline Harness Connector C133 Connector Part 12034074 Inline Harness Connector C134 Connect
14. NYO S0 pooujepufy _ esn4j ASLO uomounf ZELL NYO 90 1 soneuieuos due 1 sueis S 5 Seuil Iv JE suejs g punoJc 2001 02 LSSV Truck Systems 8 49 Lightin Body and Accessories sulojs g 5 5 uonnquisiq soneuieuos uognquisia LS suiejs s ges 08 Joes uonounr V e 90 veel NYS 17 5 0 ye a ume 90A f veel peel NHO L1 Nyo 11890 40 gt Apog i 42018 uonounf i LO Y LEW 4 9 NLS 1180 L veel NYS 11S 0 veel NYS 1160 LO 8 uonisod 1 esn4 jo ped r 17 8 YTHL YOUMS 1 300191 dnyoeg _ uonounf 1 NYO 171 ENS DUM T 9514 uonnquisid uogounp _ _ dnyoid soneuieu s 51467 dnyoeg 2001 02 LSSV Truck Body and Accessories 8 50 Lighting Systems 5 5 B soneuleuos uonnquisia 0921 189 L P 06 1 m Ang 975 5
15. 2001 02 LSSV Truck 6 32 Engine Electrical Engine 2001 02 LSSV Truck 8 Observe the voltage on the meter and the intensity of the lamps if connected The lamps should be at full intensity The voltage should be approximately twice the 12V reading 1 5V For example if the 12V input is 12 6V the 24V output should be between approximately 24V and 27 Verify the input voltage at the 12V and 27V Verify the input voltage at the 12V terminal If voltages are less or greater than the indicated range or if the lamps are not glowing greater than half intensity return the unit to the manufacturer Sure Power for evaluation or call for a calibration 9 Disconnect the unit under test Option 1 Single 24V Battery Bank Note The following is used in addition to the Power Converter Voltage Regulator Replacement instructions as recommended by the manufacturer Sure Power Industries Inc 1 Mount the voltage regulator close to the battery bank Notice Do not connect to the chassis ground Improper operation may result 2 Connect the ground terminal directly to the 12V A battery ground 3 Connect the 12V positive terminal to the 12V A battery positive post 4 Connect the 24V output terminal to the 24V B battery positive post Notice This circuit activates the voltage regulator only and does not act as an ON OFF switch for the 24V accessories 5 Connect the ignition terminal to a 12V ignition source
16. 8292 LHM 80 5 soneujeuos uonnquisia i 1 YOUMS 1 NYO S O 696 IHM 950 L 994 sess 1 89 1 uonounr uonnquisiC Jewog 1 4 SOUL liv e 51043409 Buys 7 1nox ejg Body and Accessories 90019 6092 8 0 6092 80 6092 Nua 80 6092 5 1H tess 1 y SUZ nqa 9 80 duis 80 6092 6062 80 co lzo esnJj 11 r 74 1 dwe 8 52 Lighting Systems IHAVNHS 80 esn4 H4 YY y THL e v sili MORAN uonnquisiq punog 390l8 JOMOd uonounf 1 manz zo Co ve He 104009 Y duie1 pog 0801 LHM 660 51467 uoun ___ 091 9919 1880 8216 1619 lt 9d THO A H 25 346 2001 02 LSSV Truck Lighting Systems 8 53 Body and Accessories 1
17. Converter No Voltage Step Action Value s Yes No Schematic Reference Engine Electrical 1 Did you review the Starting and Charging System Go to Description Description and Operation Go to Step 2 and Operation Are the batteries properly charged Go to Battery Charging in 2 2001 02 Truck Service Go to Step 3 Manual Connect a test lamp between the shorter 12V stud and ground Does the test lamp illuminate Go to Step 4 Go to Step 5 Connect a test lamp between the shorter 24V stud 4 and ground Does the test lamp illuminate Go to Step 11 Go to Step 9 Connect a test lamp between the longer 12V stud 5 and ground Does the test lamp illuminate Go to Step 6 Go to Step 7 Locate and repair the source of the overload and 6 the fuse Did you complete the replacement Go to Step 25 Connect a test lamp between the output stud of 7 the 12V circuit breaker and ground Does the test lamp illuminate Go to Step 8 Go to Step 10 Locate and repair the open in circuit 152 Did you complete the repair mS Go to Step 25 gt Connect a test lamp between the longer 24V stud and ground Does the test lamp illuminate Go to Step 17 Go to Step 16 Connect a test lamp between the input stud of the 10 12 circuit breaker and ground Does the test lamp illuminate Go to Step 12 Go to Step 13 2001 02 LSSV Truck 6 26 Engine Electrical Engine Converte
18. Go to Step 21 Go to Step 22 21 Replace the horn relay Did you complete the replacement Go to Step 25 22 Disconnect the horn switch connector in the steering wheel connect a test lamp from the horn switch terminal feed side to Press the horn button Does the test lamp illuminate Go to Step 24 Go to Step 23 23 Replace the horn switch Does the test lamp light Did you complete the replacement Go to Step 25 24 Locate and repair open in BLK 28 wire between the horn switch and the horn relay or in the horn brush horn slip ring Did you complete the repair Go to Step 25 25 Verify the system operation Do the horns operate properly System OK Go to Step 2 2001 02 LSSV Truck Body and Accessories Horns 8 93 Horns Operate in Blackout B O Mode Step Action Yes No Schematic Reference Horns Schematic 1 Did you review Horns Description and Operation Go to Description Go to Step 2 and Operation 1 Disconnect blackout service drive switch 2 2 Connecta test lamp from cavity C to ground Does the test lamp illuminate Go to Step 3 Go to Step 4 Replace blackout control relay Did you complete the replacement Go to Step 5 m F Replace blackout service drive switch Did you complete the replacement Go to Step 5 5 Verify the system operation Do the horns operate properly System OK Go to Step 2 20
19. Go to Step 7 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 Battery Equalizer Inoperative Step Action Value s Yes No Schematic Reference Engine Electrical 1 Did you review the Starting and Charging System Description and Operation Go to Step 2 Go to Description and Operation Connect a test lamp between the 12V terminal of the equalizer and ground Does the test lamp illuminate Go to Step 3 Go to Step 4 Connect a test lamp between the 24V terminal and ground Does the test lamp illuminate Go to Step 6 Go to Step 5 Connect a test lamp between the output side of the 12V circuit breaker and ground Does the test lamp illuminate Go to Step 8 Go to Step 9 Connect a test lamp between terminal B of the contactor and ground Does the test lamp illuminate Go to Step 11 Refer to Contactor Inoperative Connect a self powered test lamp to the ground terminal and ground Does the test lamp illuminate Go to Step 7 Go to Step 13 Replace the battery equalize Did you complete the replacement Go to Step 14 2001 02 LSSV Truck 6 28 Engine Electrical Engine Battery Equalizer Inoperative cont d Step Action Value s Yes No Locate and repair the open or high resistance in circuit 152 Did y
20. 8 70 T Tire Hoist Shaft Extension Replacement 3 10 Tires and Wheels Description Spare Wheel Hoist 5 3 11 Repair Tire Hoist Shaft Extension Replacement 3 10 Trailer Wiring Harness Replacement 8 35 Transfer Case Description Transfer Case Vent Tube Filter 4 15 Repair Transmission Transfer Case Vent Tube Filter Replacement 4 14 Transmission Transfer Case Vent Tube Filter Replacement sss 4 14 V Vehicle Identification 2 2 0 3 Voltage Regulator 6 31 Voltmeter Repair Voltmeter 8 85 Voltmeter Blackout B O Switch Panel Replacement tte 8 85 INDEX W Weapons Mount Repair Weapons Mount Replacement Floor 8 132 Weapons Mount Replacement Upper 8 132 Weapons Support Replacement Lower 8 131 Wheel Drive Shafts Description Wheel Drive Shaft Boot Covers 4 8 Repair Wheel Drive Shafts Boot Cover 4 3 Special Tools and Equipment 4 9 Winch Repair Connector Harness Replacement La a 8 36 DR 8 37 Fron
21. Caution Refer to Battery Disconnect Caution in Cautions and Notices Remove the negative cable of the right battery and the 12V and 24V cables of the left battery Release the junction block cover tab and open the cover Remove the nut and washer holding the positive booster cable and the starter cable junction box Remove the cables Release tab 1 and lift out of slot 2 and remove junction block 3 Engine Engine Electrical 6 41 Installation Procedure 1 Install the junction block 3 into slot 2 Push until tab 1 engages in bracket Notice Refer to Fastener Notice in Cautions and Notices 2 Install the cables with flanged nut and washer Tighten Tighten the flange nut to 14 Nem 10 Ib ft 3 Close the junction block cover securely 4 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cables to 17 N m 13 Ib ft 2001 02 LSSV Truck 6 42 Engine Electrical Engine Description and Operation Battery Description 12V and 24V The engine electrical options include the slave booster receptacle a power converter voltage regulator 12 and 24 Volt circuit breakers a protection contactor and a two or three battery power system The two batteries in series provide 24V of power which is isolated by the power converter and controlled by the circuit breakers These step the power down to 12V from 24V Greater power
22. Trailer Light Connection M14 M16 Weapons Mount Transmission Transfer Case Differential Vent Filter Government Data Plate Cargo Area Troop Seats Cargo Tie Downs Cargo Cover Soft Top Combination Front or Rear Mounted Winch with Remote Control Multi mount 9 000 Ib capacity Engine Mounted High Output Auxiliary Air Compressor 70 150 psi Run Flat Tires Continuous Output 5 000 W AC DC Generator On Star amp Communications Package Cargo Locking Side Rear Access Cap Pioneer Tool Kit Permanent Front Mount Winch 12 000 Ib capacity Military Rear Receiver Hitch Factory Rear Receiver Hitch 2001 02 LSSV Truck 0 6 General Information Labels 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 24V battery This battery is on the left side of the engine compartment Winch Warning Label ALWAYS USE STRAP WHEN HANDLING HOOK TO AVOID INJURY TAG TO BE REMOVED BY COMSUMER ONLY The winch warning label is fixed to the winch cable hook 2001 02 LSSV Truck General Information Equalizer Label EQUALIZER MODEL 41204 INPUT VOLTAGE 12V OUTPUT VOLTAGE 24V OUTPUT CURRENT 40A MAX GROUND NEGATIVE S N 01000108 170498B SURE POWER wi INDUSTRIES TUALATIN OREGON 97062 Made in USA The equal
23. 1 Install the voltmeter lamp bulb to the gage Notice Refer to Fastener Notice in Cautions and Notices 2 Install the voltmeter rear bracket 2 with the two nuts 1 and washers Tighten Tighten the two nuts to 2 8 2 Ib ft 3 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 N m 13 Ib ft Body and Accessories Lighting Systems 8 81 Description and Operation Blackout B O Lighting Circuit of Operation Voltage for the blackout marker lamps is supplied through the Maxi Fuse 8 located in the under hood relay center to the battery junction block From there the ORN 40 wire and inline fuse A supply voltage to the blackout service drive switch When the blackout service switch is placed in blackout mode voltage is applied to PNK 911 wire to inline fuse B Voltage is then applied to the BRN 900 wire for front blackout marker lamps and BRN WHT 900 wire for rear blackout marker lamps Ground for the front blackout marker lamps is supplied through G113 for the front and C401 for the rear The blackout stoplamps voltage is supplied through fuse A GRN 40 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 service drive switch When in blackout mode voltage is applied from the DKGRN WHT 902 wire to the blackout stopla
24. 1 5 Ib ft Upper Weapons Mount Bolts 8 6 Ib ft 2001 02 LSSV Truck 8 126 Interior Trim Body and Accessories 2001 02 LSSV Truck Repair Instructions Rear Compartment Side Trim Panel Replacement Tahoe Suburban Removal Procedure 1 Remove the third pillar garnish molding Refer to the Trim Replacement Third Pillar in the 2001 02 Truck Service Manual 2 Remove the rear corner garnish molding Refer to the Garnish Molding Replacement Rear Corner in 2001 02 C K Truck Service Manual 3 Remove the screws holding the side trim panel to the side panel 4 Remove retainer clips holding the trim panel to the vehicle 5 Remove the side trim panel Body and Accessories Interior Trim 8 127 Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 1 Install the side trim panel with the screws Tighten Tighten the screws to 2 1 5 Ib ft 2 Install the trim panel to the vehicle by pressing on the retainer clips 3 Install the rear corner garnish molding Refer to Rear Corner Garnish Molding Replacement Rear Corner in the 2001 02 C K Truck Service Manual 4 Install the third pillar garnish molding Refer to Trim Replacement Third Pillar in the 2001 02 Truck Service Manual 2001 02 LSSV Truck 8 128 Interior Trim Body and Accessories 2001 02 LSSV Truck Floor Mat Replacement Pickup Models Removal Proced
25. 5 C 9 Connector Location 2 Cavity F 6 To Underhood Relay Harness 3 Cavity E 7 C 4 Connector Location 4 Junction Block IP 2001 02 LSSV Truck 6 20 Engine Electrical Engine 24V Cables and Circuit Breakers Legend 1 12V Circuit Breaker 6 B O Panel Harness Connector 2 24V Circuit Breaker 7 To Rear Extension Harness 3 To 24V Battery 8 Ground Stud 4 To Junction Block Underhood 9 B O Panel Harness 5 To Front Blackout Lamps 10 To 24V Converter Equalizer 2001 02 LSSV Truck Engine Engine Electrical 6 21 24 Battery Booster Connector Legend 1 Battery Positive Ground RED 3 Battery Negative Ground BLK 2 Booster Connector Assembly 2001 02 LSSV Truck 6 22 Engine Electrical Engine Connector End Views Junction Block IP C9 Starting and Charging Connector End Views Voltmeter Connector Connector Part e 12193922 Information e 6 Way F Metric Pack 280 Series Flex Lock CRM Wire Circuit No Function Pin Color Connector Part 02973781 Information e 2 Series 280 BLK A 150A 150A Voltmeter Lamp Ground Wire Circuit No Function B zx E Not Used Pin Color C Not Used A ORN 39 Voltmeter Feed D Not Used B BLK 150B Ground E PNK 39 Power Converter IGN Voltmeter Lamp F BRN 9 Voltmeter Lamp Positive Voltmeter Relay Connector Part 12110053 Inf
26. 5 Remove upper bolts 2 from the power converter bracket Remove bracket with power converter from vehicle 6 Remove power converter by removing bolts 3 Installation Procedure 1 Install power converter to bracket and tighten bolts 3 2 Install mounting bracket to vehicle and tighten lower bolts 1 and upper bolts 2 2001 02 LSSV Truck Body and Accessories Interior Trim 8 141 Notice Refer to Fastener Notice in Cautions and Notices 3 Install the wiring to the power converter terminal in the same position as removed Tighten Tighten converter connections to 12 N m 110 Ib ft 4 Install cover 1 on power converter 2 5 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 13 Ib ft Power Converter Replacement Tahoe 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 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 tight
27. A BRN 441 Pass Thru Circuit A BRN 441 Pass Thru Circuit B PPL 420 Pass Thru Circuit B PPL 420 Pass Thru Circuit C BLU 1134 Pass Thru Circuit C LT BLU 1134 Pass Thru Circuit D GRN 1135 Pass Thru Circuit D DK GRN 1135 Pass Thru Circuit WHT WHT E ORN 1540 Pass Thru Circuit E ORN 1540 Pass Thru Circuit WHT 913 Stop Lamp Switch F WHT 17 Stop Lamp Switch Signal Signal G LT GRN 584 Pass Thru Circuit G LT GRN 584 Pass Thru Circuit H GRY 48 Pass Thru Circuit H GRY 48 Pass Thru Circuit Inline Harness Connector C155 Inline Harness Connector C155 Connector Part e 12129136 information 4 Way F Flex Lock 280 Series BLK Wire Circuit No Function Pin Color A ORN 240 Park Lamps B WHT 352 Head Lamps C ORN 40 CTSY Lamps D PNK 839 Back Up Lamps 2001 02 LSSV Truck Connector Part e 12129135 Information 4 Way 280 Series BLK Wire Circuit No Function Pin Color A ORN BLK 240B Park Lamps B WHT 352B Head Lamps C ORN 40B CTSY Lamps D PNK 839B Back Up Lamps Body and Accessories Inline Harness Connector C202B Wiring 8 2 Inline Harness Connector C202B 9 Connector Part 12064998 Connector Part 15358651 Information 8 Way F MIP Series 280 Information e 8 Way MIP Series 280 BLK BLK Wire Circuit No Function Wire Circuit No Function
28. Pin Color Pin Color A BRN 441 Pass Thru Circuit A BRN 441 Pass Thru Circuit B PPL 420 Pass Thru Circuit B PPL 420 Pass Thru Circuit C LT BLU 1134 Pass Thru Circuit C BLU 1134 Pass Thru Circuit D DK GRN 1135 Pass Thru Circuit D LT GRN 1135 Pass Thru Circuit WHT WHT E ORN 1540 Pass Thru Circuit E ORN 1540 Pass Thru Circuit WHT 17 Stop Lamp Signal F WHT 17 Stop Lamp Switch G LT GRN 584 Pass Thru Circuit G LT GRN 584 Pass Thru Circuit SER H GRY 48 Pass Thru Circuit H GRY 48 Pass Thru Circuit Inline Harness Connector C135 Inline Harness Connector C135 c A B 10794 Connector Part e 12129081 Information 2 Way F Flex Lock 280 Series BLK Wire Circuit No Function Pin Color A DK BLU 545 DRL B DK GRN 1329 Horn 10793 Connector Part e 12129155 Information 2 Way MIP 280 Series BLK Wire Circuit No Function Pin Color A DK BLU 545A DRL B DK GRN 1329B Horn 2001 02 LSSV Truck 8 30 Wirin Body and Accessories Inline Harness Connector C192 Inline Harness Connector C192 Inline Harness Connector C191 ON B A 10573 Connector Part 12010973 Connector Part e 12015792 Information 2 Way F Weather Pack Information e 2 Way M Weather Pack SHD BLK TWR BLK Wire Circuit No Function Wire Circuit No Function Pin Color Pin Color A PNK 139A Ignition 1 Voltage In A PNK 139A Turn Signal Rel
29. service light blackout switch remains in the ON or down position Pulling the left blackout drive light switch out and right 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 are function tables for the service light blackout control switch and determines under what conditions various exterior and interior lighting functions activate Additional details are found in the Owner s Manual 2001 02 LSSV Truck 8 82 Lighting Systems Body and Accessories Exterior Lights Exterior Lamp or Device Service Switch Blackout Drive Light Switch Headlamps and Taillamps ON OFF Daytime Running Lamps ON OFF Fog Lamps If Equipped ON OFF Parking Lamps ON OFF Front Rear Sidemarker Lamps ON OFF Marker Lamps Roof Fender and ON OFF Tailgate If Equipped Brakelamps ON OFF Back up Lamps ON OFF License Plate Lamp If Equipped ON OFF Front Rear Turn Signals ON OFF Hazard Warning Lamps ON OFF Cargo Lamp If Equipped ON OFF Horn ON OFF Front Rear Blackout Marker Lamps B O ON OFF Blackout Stoplamps B O ON OFF Blackout Drive Lamp Headlamp B O ON General Description Interior Lights Interior Lamp or Device Service Switch Blackout Drive Light Switch Instrument Panel Switch Illumination ON OFF Radio Clock ILLUMINATION ON OFF If Equipped Headlamp High Beam
30. 1 Slave Start Receptacle 3 Negative Connection to Engine Block 2 Negative Cable 4 Positive Cable to Junction Block 2001 02 LSSV Truck 5 Body and Accessories Wiring 8 17 Winch Harness Routing Rear Legend 1 Harness to Junction Block 3 Rear Frame 2 Winch Connector 2001 02 LSSV Truck Body and Accessories 8 18 Wirin Power Converter Legend o o 2 ERS FEE um 0 0 S Eg Paz O ew We 2001 02 LSSV Truck Body and Accessories Wiring 8 19 Battery Equalizer 245 Legend 1 24V Terminal 4 Battery Equalizer 2 12V Terminal 5 LED Status Indicator 3 Ground Terminal 2001 02 LSSV Truck 8 20 Wirin Converter Protection Contactor Starter Relay ms gt Y gt Body and Accessorie Legend 1 Boot 6 From the Ignition Stud Power Converter 2 24V Equalizer Stud 7 Ground from Power Converter 3 Contactor Starter Relay 8 From 24V Circuit Breaker 4 24V Converter Stud 9 From Circuit Breaker 24V Converter Stud 5 Engine Wiring Harness 2001 02 LSSV Truck 5 Body and Accessories Wiring 8 21 Front Winch Harness Routing Legend 1 Positive Cable Connection 4 Front Winch Connector 2 Negative Cable Connection 5 Front Winch Harness 3 To Rear Winch Connector 6 12V Battery 2001 02 LSSV Truck 8 22 Wirin Body and Accessories
31. 6 Confirm all connections Single battery bank A and B batteries should be connected in series 7 Connect all 12V loads to the A battery positive post Connect all 24V loads to the B battery positive post Engine Engine Electrical 6 33 Option 2 Separate 24V Battery Bank Note The following is used in addition to the Power Converter Voltage Regulator Replacement as recommended by the manufacturer Sure Power Industries Inc 1 Mount the Voltage regulator close to the main 12V chassis battery Notice Do not connect to the chassis ground Improper operation may result 2 Connect the ground terminal directly to the 12V chassis battery ground 3 Connect the 12V positive terminal to the 12V chassis battery positive post Notice Do not connect the 12V loads to the A battery of the 24V battery bank An imbalance condition will result affecting the battery life 4 Connect the 24V output terminal to the 24V B battery positive post 5 Connect the ignition terminal to a 12V ignition source 6 Confirm all connections Maintain a separate 24V battery bank for 24V loads only Testing 1 Start the engine 2 Assure that 12V are present at the IGN terminal of the voltage regulator Apply 10 amps of 24V load Measure the 12V input voltage and the 24V output voltage The 24V output voltage should be two times the 12V input voltage The tolerance is 0 3V 5 Adjust if required 2001 02
32. 8 121 TD DIM 8 122 Specifications cena nei 8 122 Repair Instructions 8 123 Seat Replacement Troop Pickup Models 8 123 Description and Operation 8 124 Troop Seats 8 124 Interior Trim 8 125 04 2 11 2 8 125 Repair 8 126 Rear Compartment Side Trim Panel Replacement Tahoe Suburban 8 126 Floor Mat Replacement Pickup Models 8 128 Floor Mat Replacement Tahoe Suburban 8 129 2001 02 LSSV Truck 8 2 Table of Contents Body and Accessories Government Vehicle Data Plate Replacement 8 130 Weapons Support Replacement Lower 8 131 Weapons Mount Replacement Upper 8 132 Weapons Mount Replacement Floor Mount 8 132 24 Voltmeter Relay Replacement Pickup 8 133 24 Voltmeter Relay Replacement Tahoe 8 134 24 Voltmeter Relay Replacement Suburban 8 135 Contactor Replacement Pickup Models 8 136 Contactor Replacement Tahoe 8 138 Contactor Replacement Suburban 8 138 Power Converter Bracket Replacement Pickup 8 140 Power Converter
33. 8 155 Cargo Cover Top Bows Replacement 8 156 Cargo Tie Down Eye Replacement 8 158 Circuit Breaker Repair Circuit Breaker Bracket Replacement 6 39 Circuit Breaker Replacement 12V or 24V 6 37 Clevis Tie Down Repair Clevis Tie Down Support Replacement Front Utility 8 105 Clevis Tie Down Bracket Replacement Rear 8 113 Clevis Tie Down Bracket Replacement Rear Utility Extended Cab 8 112 Clevis Tie Down Replacement Front 8 103 Clevis Tie Down Replacement Rear 8 114 Clevis Tie Down Support Replacement Front Pickup 8 104 Clevis Tie Down Support Replacement Front geeta 8 105 Clevis Tie Down Support Replacement Rear Factory Hitch Pickup Models 8 112 Contactor Repair Contactor Replacement Pickup Models 8 136 Contactor Replacement Suburban 8 138 Contactor Replacement Tahoe 8 138 E Engine Electrical Components Starting and Charging Component Views 6 9 Starting and Charging Connector End Views 6 22 Description Battery 12V and 24V sss 6 42 Starting and Charging System 6 42 Diagnosis Battery Equalizer Inoperative 6 27 Contactor In
34. 8 33 Auxiliary Lamp Harness Replacement Front 8 32 Axle Description Front Axle Vent Tube Filter Description 4 11 Rear Axle Vent Tube Filter Description 4 13 Repair Front Axle Vent Tube Filter Replacement 4 10 Rear Axle Vent Tube Filter Replacement 4 12 B Backup Lamps Description Backup Lamps Circuit of 8 81 Diagnosis Backup Lamps Inoperative 8 68 Backup Lamps Operate in Blackout B O eint b 8 73 Battery Description Battery Description 12V and 24V 6 42 Repair Battery Booster Slave Junction Block 6 40 Battery Equalizer Replacement Suburban 8 145 Battery Equalizer Replacement Tahoe 8 144 Battery Equalizer Bracket Replacement Pickup Models 8 143 Battery Tray Battery Replacement 6 39 Blackout B O Lighting Blackout Headlamp Always On 8 68 Description Blackout Lighting Circuit of Operation 8 81 Blackout Lighting Description 8 81 Diagnosis Blackout Headlamp Inoperative 8 66 Repair Blackout Switch Replacement 8 86 Voltmeter Blackout B O Switch Panel Replacement onte 8 85 Blackout B O Marker Lamps Diagnosis Blackout B O Marker
35. Coatings at 1 818 549 7772 2001 02 LSSV Truck 8 162 Frame and Underbody Body and Accessories Frame and Underbody Specifications Fastener Tightening Specifications Specification Application Metric English Receiver to Bumper Bolts 125 92 Ib ft Receiver to Frame Bolts 125 92 Ib ft 2001 02 LSSV Truck Body and Accessories Frame and Underbody 8 163 Repair Instructions Military Rear Receiver Hitch Replacement Removal Procedure 1 Remove the hitch from the receiver 2 Remove the clevis mounts Refer to Clevis Tie Down Support Replacement Rear Factory Hitch Pickup Models 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 Installation Procedure 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 92 Ib ft 4 Install the clevis mounts Refer to Clevis Tie Down Bracket Replacement Rear Crewcab in the Bumpers section 5 Install the hitch in the receiver Front Winch Receiver Replacement Removal Procedure 1 Remove front bumper Refer to Front Bumper Replacement Tahoe Suburban or Front Bumper Replacement Pickup Models in Bumpers 2 Remo
36. Department Phone Number General Information 1 248 680 5214 Military Service Parts Assistance 1 248 680 5222 Technical Warranty Assistance 1 248 680 2843 Vehicle Sales 1 248 680 5222 Mailing Address GM Defense Military Trucks MC 483 619 114 1996 Technology Drive Troy MI 48083 Preface Preface 5 2001 02 SERVICE MANUAL SUPPLEMENT COMMENT FORM Use this form to advise us of any errors you might find in this manual We also welcome suggestions for improving this Service Manual Supplement Service Manual s that have the error Page number s that have the error Graphic number s that have the error VIN if available or model and applicable options Describe in detail the error found or the suggestion s Attach additional pages if necessary From Mail To Dealer Military Organization Name Dealer Code City Town State Name of Person Submitting This Comment Form Signature Date GM Defense Military Trucks Mail Code 483 619 114 1996 Technology Drive Troy MI 48083 USA Attention ILS Manager Table of Contents Table of Contents 1 Table of Contents Preface General Information General 0 3 Maintenance and Lubrication 0 7 Suspension Front Suspension 3 3 Rear 0 sss 3 7 Tires
37. Did you complete the repair Go to Step 20 Replace blackout headlamp Did you complete the replacement Go to Step 20 m 2001 02 LSSV Truck Body and Accessories Lighting Systems 8 67 Blackout Headlamp Inoperative cont d Step Action Yes No 1 Place blackout switch to on position 2 Connecta test lamp at CKT 901B TAN WHT wire between blackout control relay cavity 85 connector C216 and ground Does the test lamp illuminate Go to Step 8 Go to Step 9 Locate and repair open in CKT 901B TAN WHT wire between blackout lamp cavity A and blackout control relay cavity 85 connector C216 Did you complete the repair Go to Step 20 Connect a test lamp at CKT 911E PNK wire between blackout control relay cavity 87 and ground Does the test lamp illuminate Go to Step 10 Go to Step 11 Connect test lamp at CKT 915 WHT wire cavity 86 and cavity 87 of the blackout control relay Does the test lamp illuminate Go to Step 13 Go to Step 15 Connect a test lamp from blackout service drive switch cavity A CKT 911A PNK and ground Does the test lamp illuminate Go to Step 12 Go to Step 14 Locate and repair open in CKT 911A PNK between blackout service lamp switch and blackout control relay Did you complete the repair Go to Step 20 Replace blackout control relay Did you complete the replacement Go to Step 20 Connect
38. 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 2 from the equalizer 1 5 Body and Accessories Interior Trim 8 137 3 Remove the bolts 3 and nuts 1 securing the contactor 2 to the cover Notice A back up wrench must be used to hold the bottom nut stationary 4 Remove the wiring from the contactor terminals Note removal position of wiring for installation Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 1 Install the wiring to the contactor terminals in the same position as removed Notice A back up wrench must be used to hold the bottom nut stationary Tighten Tighten the larger contact terminal nuts to 5 6 Nem 45 55 Ib in Tighten Tighten the smaller coil terminal nuts to 1 2 N m 12 18 Ib in 2 Install the contactor 2 to the cover and secure with bolts 3 and nuts 1 3 Install the cover 2 to the equalizer 1 4 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 13 Ib ft 2001 02 LSSV Truck 8 138 Interior Trim Body and Accessories 2001 02 LSSV Truck Contactor Replacement Tahoe Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Remove the negative cable of the right bat
39. Down Replacement Rear 2 Remove bolt 2 from clevis mount 3 Remove nuts and bolts 1 from clevis mount 4 Remove clevis mount 3 from frame Body and Accessories Bumpers 8 113 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 67 88 49 65 Ib ft 3 Install bolt 2 and tighten Tighten Tighten bolt to 88 115 Nem 65 85 Ib ft 4 Install the rear clevis Refer to Clevis Tie Down Replacement Rear Clevis Tie Down Bracket Replacement Rear Crewcab Removal Procedure 1 Remove the rear clevis Refer to Clevis Tie Down Replacement Rear 2 Remove bolts 1 and nuts 2 3 Remove clevis tie down bracket from the receiver Installation Procedure 1 Install clevis tie down bracket in receiver 2 Install bolts 1 and nuts 2 and tighten 3 Install the rear clevis Refer to Clevis Tie Down Replacement Rear 2001 02 LSSV Truck Body and Accessories 8 114 Bumpers Pintle Hook Replacement Removal Procedure Note This procedure is the same for the factory receiver 1 Remove the spring clip from the retaining pin 2 Remove the retaining pin from the receiver 3 Pull the tow hook out of the receiver Installation Procedure 1 Push tow hook into receiver until holes line up 2 Install retaining pin into hole 3 Install spring clip into
40. Indicator ON OFF Turn Signal Hazard Warning Indicators ON OFF Four Wheel Drive Indicator ON OFF Dome Courtesy Lamps ON OFF Ashtray Lamp ON OFF Glove Compartment Lamp ON OFF Underhood Lamp ON OFF Warning Chime Headlamps On Safety ALL POSITIONS OFF Belt and Key in Ignition Instrument Cluster Warning Lights ON ON OFF Clock numerals and DRL indicator will remain illuminated 2001 02 LSSV Truck Body and Accessories Lighting Systems 8 83 Interior Lights Mechanical Device Service Switch Blackout Drive Light Switch Brake Transmission Shift Interlock ON ON OFF BTSI Torque Converter Lockup Clutch ON ON OFF 2001 02 LSSV Truck 8 84 Instrument Panel Gages and Console Body and Accessories Instrument Panel Gages and Console Specifications Fastener Tightening Specifications Specification Application Metric English Battery Cable Connections 17 N m 13 Ib ft Blackout Switch Nuts 2 8 2 Ib ft Voltmeter Bolts 2 8 2 Ib ft 2001 02 LSSV Truck Body and Accessories Instrument Panel Gages and Console 8 85 Repair Instructions Voltmeter Replacement 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 cables of the left battery 2 Remove the connector 3 and the bulb harness from the back of the voltmeter and mounting bracket 3
41. LSSV Truck 6 34 Engine Electrical Engine NATO Slave Cable 2001 02 LSSV Truck Adjustment The voltage adjustment will allow adjustment of the 24V output with respect to the 12V This adjustment is preset at the factory If adjustment is necessary it should be made when normal charge voltage is present at the 12V battery 14V Adjust the 24V under light load to 27 5 to 28V An isolator may be used in the 24V output If this is done the 24V must be adjusted to compensate for the isolator Notice 24V loads drawing current in excess of the rating of the voltage regulator are permissible for short periods of time only minutes Prolonged use of these loads will result in improper battery charge and eventual battery deterioration 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 start In the event the system must be replaced refer to Slave Connector Replacement in Body Front End 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
42. LSSV Truck 8 156 Body and Accessories 2001 02 LSSV Truck Cargo Cover Top Bows Replacement Removal Procedure 1 Remove the cargo cover Refer to Cargo Cover Replacement 2 Remove the strap tensioners from the front and rear top bows by withdrawing from the side rail loop 3 Remove the six pins 1 holding the three top bows to the six side struts 4 Remove the three top bows from the struts 5 Slide the strap off each top bow Remove the bows from the vehicle Installation Procedure 1 Slide the strap onto the top bows at the center 2 Attach the retainer pin 1 assembly as shown at the base of each bow end Notice Refer to Fastener Notice in Cautions and Notices 3 Attach the retainer cover strap assembly 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 two cover strap retaining nuts to 5 N m 4 Ib ft 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
43. Lamps Inoperative 8 70 Blackout Lighting Diagnosis Headlamps Operate in Blackout Mode 8 68 Blackout Marker Lamps Diagnosis Blackout Marker Lamps Always 8 71 Body Front End Description Body Front End Description 8 121 Repair Slave Connector Replacement 8 118 Winch Mount Replacement Pickup Models 8 118 Winch Replacement Pickup Models 8 119 Specifications Fastener Tightening 8 117 Body Rear End Description Body Rear 8 160 Repair Cargo Cover Front End Rail Replacement 8 153 Cargo Cover Rear End Rail Replacement 8 154 Cargo Cover Replacement 8 157 Cargo Cover Side Rail and Hinge Replacement 8 151 Cargo Cover Stowage Replacement 8 159 Cargo Cover Strut Replacement 8 155 Cargo Cover Bows Replacement 8 156 Cargo Tie Down Eye Replacement 8 158 Fiberglass Top Replacement 8 157 License Plate Bracket Replacement 8 151 Specifications Fastener Tightening 8 150 Bumpers Description 8 116 Repair Bumper Replacement Rear Military Hitch 8 109 Bumper Replacement Rear Factory
44. On the power converter Engine Electrical Engine Electrical Component Views in Connector End Views in Engine Electrical Engine Electrical C133 In the upper LH of engine compartment Wiring Component Wiring Connector End Views in Wiring Systems Views in Wiring Systems C134 In the upper LH of engine compartment Wiring Component Wiring Connector End Views in Wiring Systems Views in Wiring Systems C135 In the lower LH of engine compartment Wiring Component Wiring Connector End Views in Wiring Systems Views in Wiring Systems C202A In auxiliary IP harness at stoplamp switch Wiring Component Wiring Connector End Views in Wiring Systems Views in Wiring Systems C202B In auxiliary IP harness at stoplamp switch Wiring Component Wiring Connector End Views in Wiring Systems Views in Wiring Systems C155 Interrupt relay block RH engine Wiring Component Wiring Connector End compartment Views in Wiring Systems Views in Wiring Systems C135 Interrupt relay block RH engine Wiring Component Wiring Connector End compartment Views in Wiring Systems Views in Wiring Systems C241 To convenience center Wiring Component Wiring Connector End Views in Wiring Systems Views in Wiring Systems C932 Center under endgate to RR lamp Wiring Component Wiring Connector End extension Views in Wiring Systems Views in Wiring Systems C917 Center under endgate inline to trailer Wiring Component Wiring Connector End harness Views in Wiring Systems Views in Wiring System
45. Remove the two nuts 1 from the back of gage Remove bracket 2 5 Remove voltmeter 4 from opening gt Installation Procedure 1 Install the voltmeter 4 in the bracket opening 2 Install bracket 2 on back of voltmeter Notice Refer to Fastener Notice in Cautions and Notices 3 Install nuts 1 and tighten Tighten Tighten nuts to 2 8 N m 2 Ib ft 4 Connect connectors 3 and the bulb harness to the gage 5 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten the battery cable connection to 17 N m 13 Ib ft Voltmeter Blackout B O Switch Panel Replacement 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 cables of the left battery 2 Remove the voltmeter Refer to Voltmeter Replacement 3 Remove the blackout switch Refer to Blackout B O Switch Replacement 4 Remove the screws 1 holding the panel to the IP Left side shown right side similar 2001 02 LSSV Truck 8 86 Instrument Panel Gages and Console Body and Accessories Installation Procedure 1 Install the panel on the IP Hand tighten the screws 1 Left side shown right side similar 2 Install the blackout switch to the panel Refer to Blackout B O Switch Replacement 3 Install the voltmeter to the panel Refer to Voltmeter Replacement N
46. Replacement Upper 8 132 Weapons Support Replacement Lower 8 131 Specifications Fastener Tightening Specifications 8 125 Compartment Lamp Replacement Voltmeter 8 80 J Jump Starting in Case of Emergency 6 34 L Label 24V Battery Caution Label 0 6 26 te ht nie eh 0 6 Owner User s 0 6 Winch Warning 0 6 Lamp Harness Replacement Rear 8 34 License Plate Bracket Replacement 8 151 Lighting Systems Components Lighting Systems Component Views 8 54 Lighting Systems Connector End Views 8 63 Description Backup Lamps Circuit of Operation 8 81 Blackout Lighting 8 81 Blackout B O Lighting Circuit of Operation 8 81 Diagnosis Backup Lamps lnoperative 8 68 Backup Lamps Operate in Blackout B O e eet tp Hrs 8 73 Blackout Headlamp Always 8 68 Blackout Headlamp Inoperative 8 66 Blackout B O Marker Lamps Always On 8 71 Blackout Marker Lamps Inoperative 8 70 CTSY Lamps Operate in Blackout B O DRL Operate in Blackout 8 72 Headlamps Oper
47. Replacement Suburban 8 142 Power Converter Replacement 8 141 Power Converter Bracket Replacement Pickup 8 140 Power Converter Equalizer Bracket Replacement Tahoe 8 146 Power Converter Equalizer Bracket Replacement Suburban 8 147 R Radiator Repair Radiator Grille Brush Guard Replacement 8 103 Radiator Grille Replacement 8 96 Rear Compartment Side Trim Panel Replacement Tahoe Suburban 8 126 Rear Drive Axle Description Rear Axle Vent Tube Filter 4 13 Repair Rear Axle Vent Tube Filter Replacement 4 12 Rear Suspension Description Rear Shock Absorber 3 9 Repair Shock Absorber Replacement 3 8 Specifications Fastener 3 7 Relay Mounting Bracket Replacement 8 37 5 Schematics Engine 6 3 Ine ce PD 8 89 Lighting 8 40 WING 8 3 Seats Description Troop Seats Description 8 124 Repair Seat Replacement Troop Pickup 8 123 Specifications Fastener
48. S282 Approx 34 5 cm right of inline IP harness connector breakout 402 Approx 25 cm left of trailer connection m jumper 5403 Approx 40 0 cm left of taillamp extension EE EE breakout 5407 Approx 45 0 cm left of trailer connector jumper harness breakout 5408 Approx 37 5 cm right of taillamp extension breakout 5412 Fleetside Approx 45 cm right of taillamp extension breakout 5422 Approx 5 cm right of trailer connection jumper 2001 02 LSSV Truck Body and Accessories Wiring 8 13 Power and Grounding Component Views Rear Lamp Harness Legend 1 C992 6 C917 2 Auxiliary Rear Lamp Extension Harness 7 C993 3 Rear Lamp Extension Harness 8 To B O Marker Lamp LH 4 Taillamp Connector 9 Ground 5 To B O Marker Lamp RH 2001 02 LSSV Truck 8 14 Wirin Body and Accessories Forward Blackout B O Lamp Harness Legend 1 C192 4 To B O Headlamp 2 Forward Lamp Harness 5 To B O Marker Lamp LF 3 6113 6 To B O Marker Lamp RF 2001 02 LSSV Truck Body and Accessories Wiring 8 15 Voltmeter and Lamp Legend 1 Voltmeter Bracket 4 Voltmeter 24V 2 Mounting Bracket 5 Voltmeter Illumination Bulb 3 Voltmeter Connector 6 Harness Connector 2001 02 LSSV Truck 8 16 Wirin Body and Accessorie Slave Start Harness Routing P ESL TM VEN 9 YL N A Legend
49. a test lamp from the blackout service lamp switch at cavity B CKT 40A ORN and ground Does the test lamp illuminate Go to Step 19 Go to Step 18 1 Disconnect blackout headlamp switch 2 Connect a self powered test lamp between blackout headlamp switch cavity E CKT 150C BLK and ground Does the test lamp illuminate Go to Step 16 Go to Step 17 Replace blackout headlamp switch Did you complete the replacement Go to Step 20 Locate and repair open in CKT 150C BLK wire between blackout headlamp switch and ground Did you complete the repair Go to Step 20 Locate and repair open in CKT 40A ORN wire between connector C241and blackout service lamp switch cavity B Did you complete the repair Go to Step 20 Replace blackout service drive switch Did you complete the replacement Go to Step 20 20 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 2001 02 LSSV Truck 8 68 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 service lamp switch in all out mode Connect a test lamp between blackout service drive switch cavity A 2 CKT 911C PNK to ground
50. and Wheels 2 3 10 Driveline Axle Wheel Drive 4 3 Front Drive eese 4 10 Rear Dive Axle 4 12 En eee 4 14 Engine Engine Electrical tsi reed 6 3 Body and Accessories Wiring 5 mme 8 3 Lighting Systems 222 22 8 40 Instrument Panel Gages and Console 8 84 eon 8 89 Exterior 00 22 8 95 n erected 8 99 Body Front End eee 8 117 SILICET 8 122 t eerie dt 8 125 Body eus 8 150 8 161 Frame and 8 162 INDEX atat Mati MN INDEX 1 2001 02 LSSV Truck General Information Table of Contents 0 1 Section 0 General Information General Information 0 3 Maintenance and Lubrication 0 7 Vehicle Identification 0 3 Maintenance irent 0 7 Military Equipment Options 0 5 Owner Checks and 0 7 2001 02 Commercial Utility Cargo Vehicle Periodic Maintenance Inspection 0 7 LSSV Specificatio
51. behind the brake booster Lighting Component Views in Lighting Systems Lighting Connector End Views in Lighting Systems Blackout Service Drive Switch In the center lower IP Lighting Component Views in Lighting Systems Lighting Connector End Views in Lighting Systems Blackout Switch In the center lower IP Lighting Component Lighting Connector End Headlamp Views in Lighting Views in Lighting Systems Systems Blackout Stop Marker In the left front grille Lighting Component Lighting Connector End Lamp LH Views in Lighting Views in Lighting Systems Systems Blackout Stop Marker In the left front grille Lighting Component Lighting Connector End Lamp RH Views in Lighting Views in Lighting Systems Systems Blackout Stop Marker At the LH of the rear bumper Lighting Component Lighting Connector End Lamp LR Views in Lighting Views in Lighting Systems Systems Blackout Stop Marker At the RH of the rear bumper Lighting Component Lighting Connector End Lamp RR Views in Lighting Views in Lighting Systems Systems Circuit Breaker 12V In the engine compartment on the LH fender brace Lighting Component Views in Lighting Systems Lighting Connector End Views in Lighting Systems Circuit Breaker 24V In the engine compartment on the LH fender brace Lighting Component Views in Lighting Systems Lighting Connector End Views in Lighting Systems Power Converter Protect
52. hurt you Notice lgnoring these steps could result in costly damage to the vehicle Trying to start your vehicle by pushing or pulling it won t work and it could damage your vehicle You should always use the NATO Slave Receptacle and Slave Cable when performing this operation Engine Engine Electrical 6 35 1 Get vehicles close enough so the slave cable can reach but be sure the vehicles aren t touching each other If they are it could cause a ground connection you don t want You wouldn t 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 an automatic transmission in PARK P or a manual transmission vehicle be sure the transfer case is NEUTRAL 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 10555 Caution Using a match 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 Delco Freedom battery or batteries in
53. in a predominately 24V system which requires clean regulated 12V power The Battery Equalizer can deliver up to 150 amps of continuous clean 12V current for practically any 12V load such as two way radios blackout lighting and other military options 24V Voltmeter Voltage is available through CKT 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 at G200 through the convenience center The voltmeter needle should be in the green band during normal load operation During no load situation the voltmeter needle should be between the yellow and green bands 2001 02 LSSV Truck Body and Accessories Table of Contents 8 1 Section 8 Body and Accessories Wiring Systems 8 3 Specifications eere 8 3 Schematic and Routing Diagrams 8 3 Component 8 10 Power Grounding Component Views 8 13 Connector End Views eene 8 25 Power and Grounding Connector End Views 8 25 Repair 2 1 8 32 Auxiliary Lamp Harness Replacement Front 8 32 Auxiliary Lamp Extension Harness Replacement Rear 8 33 Lamp Harness Replacem
54. is needed for the higher load used by optional radio communications the 24V starter or for compatibility with other booster slave receptacles on other vehicles Refer to 2001 02 C K 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 connection from any vehicle similarly equipped This 24V system requires specific maintenance Each power converter panel contains a circuit breaker Refer to Circuit Breaker Replacement 12V or 24V Note Repairs in this manual are limited to the specific military equipment included in the LSSV options most commonly ordered Starting and Charging System Description and Circuit Operation Starter Battery voltage is available at all times through fuse 6 located in the underhood fuse relay center Voltage is made available at the ignition switch through CKT 242 RED wire When the ignition switch is placed in start contacts in the switch close to apply voltage to the crank fuse 8 of the fuse block From the crank fuse voltage is sent on CKT 806 PPL to the transmission range switch for automatic transmission If the automatic transmission is in the park or neutral position contacts are closed which applies voltage to the CKT 1035 PPL wire at pin G of the transmission range switch The CKT 1035 PPL wire
55. of the equalizer 1 6 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections 17 13 Ib ft 1 Dr y SS lt Battery Equalizer Replacement Tahoe 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 cables of the left battery 2 Remove the power converter Refer to Power Converter Replacement Tahoe 3 Remove the cover from the side panel to gain access to the equalizer 4 Remove the bolts 3 securing equalizer 4 to mounting bracket 5 Remove wiring connections from the equalizer Note removal position of wiring for installation 2001 02 LSSV Truck Body and Accessories Interior Trim 8 145 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 the equalizer connections to 12 N m 110 Ib in 2 Install equalizer 4 on mounting bracket and tighten bolts 3 3 Install top trim cover on panel 4 Install the power converter Refer to Power Converter Replacement Tahoe 5 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 13 Ib ft Bat
56. relay and ground Does the test lamp illuminate Go to Step 14 Go to Step 12 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 13 Replace the bulbs Did you complete the repair Go to Step 17 14 Replace the interrupt relay Did you complete the repair Go to Step 17 15 Locate and repair the open or high resistance in circuit 24 or 839A Did you complete the repair Go to Step 17 16 Replace the backup lamp switch Did you complete the replacement Go to Step 17 17 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 2001 02 LSSV Truck 8 70 Lighting Systems Body and Accessories 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 Inspect the fuse s check for damaged or corroded inline connectors check for broken or partially broken wires inside 2 insulation and properly installed aftermarket equipment Did you find the condition Go to Step 3 Go to Step 4 Make necessary repairs Did you complete the repairs Go to Step 11 1 Disconnect blackout servi
57. the cargo cover Refer to Cargo Cover Replacement Body and Accessories Body Rear End 8 157 Cargo Cover Replacement Removal Procedure 1 2 Unsnap and unzip the corners of the front and rear flaps and roll the cargo cover up over the top Remove the cargo cover from the side rail and end gate retainers by releasing tension and removing hook Pull cover free Untie release or unbuckle all cover retainers Remove the cargo cover Installation Procedure Important All trailing edges must fall to the proper length at each side of the box rail All tether ties must appear on the interior Provide adequate slack between the bow straps and the cover The new cover will be a tighter fit 1 2 Install the cargo cover to the top bows and align so that the zippers are at the corners Install or attach all interior retainers to the bows struts and loops Zip the flaps down and snap on as needed Install the cover to the front end and side in hooks and pull strap at the base of the cover as needed Fiberglass Top Replacement Removal Procedure 1 2 Remove electrical connection for light if equipped Remove bolts 1 securing cap to bed rails Left side shown right side similar With the aid of an assistant remove the top from the vehicle Remove old foam tape from bed rails 2001 02 LSSV Truck 8 158 Body Rear Body and Accessories Installation Procedur
58. the circuit breakers and relays All auxiliary harnesses are outlined in schematics Several are described in repair procedures in this manual Access to fuses can be found on the power converter voltage regulator under the dash and under the hood 2001 02 LSSV Truck 8 40 Lighting Systems Body and Accessories Lighting Systems Specifications Fastener Tightening Specifications Specification Application Metric English Battery Cable Connections 17 N m 13 Ib ft Blackout Headlamp Stud Nut 10 7 Ib ft Front Blackout Marker Lamp Nuts 2 1 5 Ib ft Rear Blackout Lamp Nuts 2 1 5 Ib ft Voltmeter Lamp Nuts 2 8 2 0 Ib ft Schematic and Routing Diagrams 2001 02 LSSV Truck Lighting Systems 8 41 Body and Accessories 0029 9 3LSL Wat uognquisiq punog 8 0 ors 9 V 962 VL06 870 009 X18 0L 69 6 E 6 V VLO6 80 U9IIMS 1 I due eowes k LHWNVL 9620 8 516 9106 LHM NHO 0 L THM 552948 _ _ AG YOUMS duiejeAug o g jo xoelg 6922 YO ANd 0 8116 ANd 36 ANd OL VO NYO 07 Iv JOH 3n0x2ejg soneuieu s 5 2001 02 LSSV Truck Body and Accessories Systems 8 42 Lightin I jdnueju oipey __ 6500 LOEL NYS
59. 0 Control Circuits Information 2 Way 280 BLK 913 Service Stoplamps Series E BRN WHT 17 Stoplamp Switch Pin Wire Circuit Function Output Color No DK PPL 902 B O Brakelamps A GRN 1301 RAP Fuse Supply BRN 900 Brakelamp Voliage PPL 19 Brake Tail Lamp B Feed RR K N Not Used B ody and Accessories B O Lamps Right Rear Lighting Systems 8 65 B O Lamps Left Rear e 12010973 Connector Part e 12010973 Connector Part Information e 2 Way M Weather Information e 2 M Weather Pack BLK Pack BLK Pin Wire Circuit Function Pin Wire Circuit Function Color No Color No A GRN 902C Service Lamp Switch A GRN 902B Service Lamp Switch WHT WHT B BRN 900C B O Lamps Fuse B GRN 900B B O Lamps Fuse WHT BRN WHT License Plate Lamp Steering Column Connector 10796 Connector Part e 12047683 Connector Part e 12010946 Information e 1 Way M Weather Pack BLK Pin Wire Circuit Function Color No A BRN 9C License Plate Lamp Information e 1 Way M 150 Series BLK Pin Wire Circuit Function Color No A PNK WHT 139B Ignition 1 Voltage 2001 02 LSSV Truck 8 66 Lighting Systems Body and Accessories Diagnostic Information and Procedures Symptom List Refer to a symptom diagnostic procedure from the following list in order
60. 01 02 LSSV Truck 8 94 Horns Body and Accessories Description and Operation Horn with Blackout B O Control Circuit Operation Voltage is applied at all times to the horn relay through the inline A fuse and the horn Mini Fuse The blackout service drive switch is used to control the horn relay Power is applied through ORN CKT 40 to the blackout service drive switch which is a normally 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 G112 the horns will sound as long as the horn switch is depressed The blackout service drive switch is used to disable the horn relay when placed in the blackout mode When the blackout service drive switch is in the ON position power to the horn relay is disrupted leaving the horns inoperative 2001 02 LSSV Truck Body and Accessories Exterior Trim 8 95 Exterior Trim Specifications Fastener Tightening Specifications Specification Application Metric English Radiator Grille Bolts 9 75 Ib in 2001 02 LSSV Truck 8 96 Exterior Trim 2001 02 LSSV Truck Body and Accessories Repair Instructions Radiator Grille Replacement Removal Procedure 1 Remove the radiator grille brush guard
61. 14 2001 02 LSSV Truck Body and Accessories Lighting Systems 8 71 Blackout Marker Lamps Inoperative cont d Step Action Yes No 1 Place blackout drive lamp in blackout mode 2 Connecta test lamp at cavity A CKT 911 PNK wire at blackout service drive switch and ground Does the test lamp illuminate Go to Step 5 Go to Step 10 Connect a test lamp between inline fuse B cavity B CKT 911 5 PNK wire and ground Does the test lamp illuminate Go to Step 7 Go to Step 6 Locate and repair open in CKT 911 PNK wire between 6 inline fuse B and blackout service drive switch Did you complete the repair Go to Step 14 Disconnect blackout marker lamp s and connect test lamp between cavity 900 BRN WHT front and 900 7 BRN WHT rear to ground Does the test lamp illuminate Go to Step 8 Go to Step 9 Replace blackout marker lamp s assembly Did you complete the replacement Go to Step 14 Locate and repair open in 900 BRN WHT front and CKT 900 BRN WHT rear wire between inline fuse B and 9 blackout marker lamp assembly Did you complete the repair Go to Step 14 Connect a test lamp between blackout service drive switch to 10 40 ORN cavity B and ground Does the test lamp illuminate Go to Step 11 Go to Step 12 d Replace blackout service drive switch Did you complete the replacement Go to Step 14 EE Connect a test lamp at MBEC juncti
62. 2001 02 GENERAL MOTORS LSSV MILITARY VEHICLES SERVICE MANUAL SUPPLEMENT Preface Preface 1 Preface Caution Caution To reduce the chance of personal injury and or property damage carefully observe the instructions that follow The service manuals of General Motors Corporation are intended for use by professional qualified technicians Attempting repairs or service without the appropriate training tools and equipment could cause injury to you or others This could also damage the vehicle or cause the vehicle to operate improperly Proper vehicle service and repair are important to the safety of the service technician and to the safe reliable operation of all motor vehicles If you need to replace a part use the same part number or an equivalent part Do not use a replacement part of lesser quality The service procedures we recommend and describe in this service manual are effective methods of performing service and repair Some of the procedures require the use of tools that are designed for specific purposes Accordingly any person who intends to use a replacement part a service procedure or a tool that is not recommended by General Motors must first establish that there is no jeopardy to personal safety or to the safe operation of the vehicle This manual contains various Cautions and Notices that you must observe carefully to reduce the risk of personal injury during service or repair Improper service or re
63. 3 Install the two 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 2001 02 LSSV Truck 8 124 Seats Body and Accessories Description and Operation Troop Seats Description The troop seats provide two benches with seating for up to four troops on each side Each bench is anchored by three sets of fasteners to each box rail The seats can be folded up using tether pins to afford more cargo space They are equipped with a safety strap which should be hooked across the rear end of the box when occupied Refer to the 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 2001 02 LSSV Truck Body and Accessories Interior Trim 8 125 Interior Trim Specifications Fastener Tightening Specifications Specification Application Metric English Battery Cable Connections 17 N m 13 Ib ft Equalizer Connections 12 110 Ib in Contactor Contact Terminal Nuts 5 6 45 55 Ib in Contactor Coil Terminal Nuts 1 2 12 18 Ib in Floor Mount Weapons Bolts 8 6 Ib ft Lower Weapons Mount Bolts 8 6 Ib ft Power Converter Connections 12 110 Ib in Side Trim Panel Screws Utility 2
64. 4 OQOODOU XO 6 7 SOOO OS 2 3 4 5 6 Body and Accessorie Remove winch cover 1 Remove positive and negative cable connection from winch Note cable routing for installation Remove the bolts 2 from the front of the winch mount Remove cable from fairlead Remove fairlead Lift winch out of mount Installation Procedure 1 Install winch in mount Verify routing position of positive and negative cables Notice Refer to Fastener Notice in Cautions and Notices Position fairlead on front of mount and install winch bolts 2 Tighten Tighten bolts to 47 54 35 40 Ib ft Install positive and negative cable and tighten Install top winch cover 1 Install lower winch bolts 1 and tighten Tighten Tighten bolts to 47 54 N m 35 40 Ib ft Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cables to 17 13 Ib ft 5 Body and Accessories Body Front End 8 121 Description and Operation Body Front End Description The body front end consists of a modified radiator grille It includes three features critical to military vehicles The slave booster is mounted in a hole cut into right side of the radiator grille The blackout headlamp is mounted in a hole cut into the left side of the radiator grille The front blackout marker lamps are
65. 8 79 3 Remove the harness connector 2 by releasing the connector tab 4 Remove the nut holding the ground lead 1 and the nut to the stud Remove the opposite nut holding the to the other stud 6 Remove the blackout 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 1 5 Ib ft 2 Install the ground lead to the stud with a nut and tighten Tighten Tighten the nut to 2 N m 1 5 Ib ft 3 Install the harness connector 2 to the lamp connector 4 Install marker lamp assembly into opening in bumper tighten nut 1 5 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 N m 13 Ib ft 2001 02 LSSV Truck 8 80 Lighting Systems Body and Accessories 2001 02 LSSV Truck IP Compartment Lamp Replacement Voltmeter 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 cables of the left battery 2 Remove the nuts 1 and washers holding the rear bracket 2 to the voltmeter 4 3 Remove the voltmeter lamp bulb from the gage Installation Procedure Important Use a standard 194 bulb for replacement
66. 9 5 Remove the winch connector from the bracket if equipped 6 Remove the retaining bolts 1 2 from the front bumper 7 Remove the brace bolt 3 from the front bumper 8 Remove the front bumper assembly from the vehicle sliding it over the winch receiver if equipped 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 63 Ib ft Tighten the bracket bolt 2 to 85 63 Ib ft Tighten the brace bolt 3 to 55 41 Ib ft 2001 02 LSSV Truck Body and Accessories Bumpers 8 101 3 Install the winch connector to mounting bracket if equipped _ 10329 4 Install front clevis Refer to Clevis Tie Down Replacement Front 5 Install the front radiator grille Refer to Radiator Grille Replacement in Exterior Trim 6 Install the radiator grille brush guard Refer to Radiator Grille Brush Guard Replacement Notice Refer to Fastener Notice in Cautions and Notices 7 Install the negative battery cable of the right battery and the 12V and the 24V cables of the left battery Tighten Tighten battery cable connections to 17 13 Ib ft Front Bumper Replacement Pickup Models Removal Procedure Caution Refer to Battery D
67. 901 Drive Lamp B O Lamps Fuse B O Headlamp Connector Part 12010105 Information e 2 Way M Weather Connector Part 12010996 Pack BLK Information 1 Way M Weather Pin Wire Circuit Function Pack BLK Color No Pin Wire Circuit Function A BRN WHT 900C B O Marker Lamps 2 9 B PNK Power to A TAN WHT 901 B O Driver Lamps Controls 2001 02 LSSV Truck 8 64 Li hting Systems B O Marker Lamp Front Connector Part 12015791 Body and Accessorie Service Lamp Switch 5 information 1 F Weather Pack BLK Pin Wire Circuit Function Color No A BRN WHT 900 B O Marker Lamps Connector Part Trailer Lamp Connector 08917884 Connector Part e 08917695 Information 6 Way F MIP Series 280 BLK Pin Wire Circuit Function Color No A PNK 911C Power to B O Control B ORN 40A Junction Block Body C ORN 912B B O Control Circuits D WHT BLK 913 Service Stoplamps E WHT 17 Stoplamp Switch Output F DK GRN 902 B O Stoplamps WHT Radio Interrupt 2001 02 LSSV Truck Information e 12 Way Weather Pack BLK Pin Wire Circuit Function Color No A BRN 900 B O Marker Lamps B YEL 18 Brake Tail Lamp Connector Part e 12129155 C BRN 90
68. A to 11 Does the test lamp illuminate Go to Step 12 Go to Step 13 m Replace the LH horn Did you complete the replacement Go to Step 25 2001 02 LSSV Truck 8 92 5 Body and Accessories Horns Inoperative cont d Step Action Yes No 13 Locate and repair open in BLK 250 wire between the LH horn and G112 Did you complete the repair Go to Step 25 14 Reconnect the LH horn connector Remove the horn relay from the horn relay socket Connect a test lamp from the horn relay cavity C3 to ground Does the test lamp illuminate Go to Step 16 Go to Step 15 15 Locate and repair open ORN 740 wire from horn Mini Fuse amp to the horn relay Did you complete the repair Go to Step 25 16 Momentarily connect a fused jumper from the horn relay cavity C3 to cavity D1 Do the horns operate Go to Step 18 Go to Step 17 17 Locate and repair open in DK GRN 29 wire between the horn relay and the LH horn Did you complete the repair Go to Step 25 18 Connect a test lamp from the horn relay cavity D3 to ground Does the test lamp illuminate Go to Step 20 Go to Step 19 19 Locate and repair open in ORN 140 and 912 wire between the stop hazard fuse cavity D3 of the horn relay Did you complete the repair Go to Step 25 20 Connect a test lamp from the horn relay cavity C1 to Does the test lamp illuminate
69. Drive Shafts Boot Cover Replacement Tools Required J 41187 Band it Type Tool Disassembly Procedure Important Be careful when removing the clamps from the halfshaft seal cover if reusing the halfshaft seal cover 1 Use side cutters to cut the halfshaft seal cover clamps 2 and the nylon strap 1 2 Slide the halfshaft seal cover 1 off of the halfshaft over the CV joint end 3 Check the halfshaft seal cover 1 for rips tears worn spots or other damage Reuse the halfshaft seal cover 1 if there is no damage visible 2001 02 LSSV Truck 4 4 Wheel Drive Shafts 2001 02 LSSV Truck Driveline Axle Assembly Procedure 1 Insert new clamps 3 into the original halfshaft seal cover 1 if you are reusing the original halfshaft seal cover 2 Slide the halfshaft seal cover 1 onto the halfshaft assembly 2 starting at the outboard CV joint end 3 Align the inboard clamp 2 on the inboard joint 1 Align the seal cover seam so the seam is straight Important Tighten the seal cover clamp 1 as tight as possible without deforming the retaining clip Clamps that are not tight enough allow the cover to slide upon the joint This causes shortened service life 4 Use J 41187 in order to tighten the inboard seal cover clamp 1 Driveline Axle 5 Rotate J 41187 toward the clip in order to bend the band onto the clip 6 Pull on the tool s cutting handle in order to cut off the excess band 7 Ham
70. Fastener Tightening Specifications Specification Application Metric English Cargo Cover Bow Strap Retaining Nuts 5 4 Ib ft Cargo Cover Front End Rail Bolts 8 6 Ib ft Cargo Cover Rail and Hinge Upward Bolts 8 6 Ib ft Cargo Cover Rail Outside Bolts 26 19 Ib ft Cargo Cover Strut Bolts 5 4 Ib ft Cargo Tie Down Eye Bolts 47 65 35 48 Ib ft 2001 02 LSSV Truck Body Rear 8 151 Body and Accessories Repair Instructions License Plate Bracket Replacement Removal Procedure 1 Remove the license plate from the bracket 2 Disconnect electrical connector from the bracket 3 Remove the bolts 1 from the bracket 4 Remove the bracket 2 from the bumper SS NS A D PAP Installation Procedure 1 Install the bracket 2 onto bumper and align the holes Install the bolts 1 through bracket and bumper Connect the electrical connector Install the license plate onto the bracket 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 Pickup Models in Seats 2001 02 LSSV Truck 8 152 Body and Accessories 2001 02 LSSV Truck Remove the four bolts and nuts holding the two rail adapter plate
71. Inline Harness Connector C993 Inline Harness Connector C993 Connector Part e 12010717 Connector Part 12015793 Information 3 Way F Weather Pack Information 3 M Weather Pack SHD SHD Wire Circuit No Function Wire Circuit No Function Pin Color Pin Color A GRN 9B Park Lamp Feed BRN 9B Park Lamp Feed B DK GRN 902D B O Stop Lamps B PPL 902D B O Stop Lamps Wi PPL 192 S T Lamp Feed RR BRN 19C S T Lamp Feed RR Inline Harness Connector C932 Inline Harness Connector C932 Connector Part 12020832 Information 4 Way Weather TWR BLK Wire Circuit No Function Pin Color A BRN 9A Park Lamps B YEL 18C S T Lamps C BLK 1500 Ground D DK GRN 19C S T Lamps Connector Part e 12020830 Information e 4 Way M Weather Pack SHD BLK Wire Circuit No Function Pin Color A BRN 2109 Park Lamps B YEL 1618 S T Lamps C WHT 22 Ground D DK GRN 1619 S T Lamps 2001 02 LSSV Truck 8 28 Wirin Inline Harness Connector C202A Body and Accessorie Inline Harness Connector C202A Connector Part 12064998 Connector Part 15358651 Information 8 Way F MIP Series 280 Information e 8 Way MIP Series 280 BLK BLK Wire Circuit No Function Wire Circuit No Function Pin Color Pin Color
72. Legend 1 B O Lamp Assembly 3 Rear Lamp Harness Connector 2 Rear Bumper 2001 02 LSSV Truck 8 60 Lighting Systems Body and Accessories Front Blackout B O Marker Lamps Legend 1 B O Lamp Assembly 3 Forward Lamp Harness 2 Front Grille 2001 02 LSSV Truck Body and Accessories Lighting Systems 8 61 Blackout B O Headlamp Legend 1 Brace Assembly 4 Ground Lead 2 Blackout Headlamp 5 Fastening Nut 3 Wiring Harness Connector 2001 02 LSSV Truck 8 62 Lighting Systems Body and Accessories Relay Block Legend 1 Back Up Lamp Relay 5 Headlamp Relay 2 Park Lamp Relay 6 DRL Relay 3 CTSY Relay 7 Horn Relay 4 Harness TXO 17535 2001 02 LSSV Truck Body and Accessories Lighting Systems 8 63 Connector End Views B O Drive Lamp Switch Lighting Systems Connector End Views B O Control Relay 57 E 10566 Connector Part e 08911352 Information 5 Series 56 BLK Pin Wire Circuit Function Connector Part 12129716 Color No Information e 5 Way F MIP Series A AM __ Not Used 630 BLK B 901E Drive Lamp Pin Wire Circuit Function WHT Color No C PNK 911B Power to B O Control 86 WHT 915 B O Relay Feed from Switch to B O Relay B O Control Switch Feed 85 TAN WHT 9018 Drive Lamp D WHT 915 Stop Lamps 87 PNK 911 Power to B O E BENS ISC Ground Controls 30 BRN WHT
73. Refer to Radiator Grille Brush Guard Replacement in the Bumper section 2 Remove the upper grille baffle 3 Remove the fasteners holding the radiator grille to the radiator support 4 Remove the radiator grille Installation Procedure 1 Modify the new radiator grille using a hole saw Cut a 82 55 mm 3 25 in diameter hole 3 in the designated area left of the right headlamp for the battery booster slave connector Cut another 152 4 mm 6 00 in diameter hole 1 in the designated area of the left headlamp for the blackout headlamp Cut opening 2 in the designated area between headlamp and turn signal for the marker lamps Body and Accessories Exterior Trim 8 97 2 Paint the new radiator grille Refer to Paint Codes in Paint Coatings section 3 Install the radiator grille and bolts Notice Refer to Fastener Notice in Cautions and Notices 4 Install the upper grille baffle Tighten Tighten bolts to 9 Nem 75 Ib in 5 Install the radiator grille brush guard Refer to Radiator Grille Brush Guard Replacement in the Bumper section 2001 02 LSSV Truck 8 98 Exterior Trim Body and Accessories Description and Operation Exterior Trim Description The exterior grille has been modified to accept the blackout headlamp marker lamps and the slave start receptacle The front emblem has been removed and the grille is painted 2001 02 LSSV Truck Body and Accessories Bumpers 8 99 Bumpers Specification
74. Replacement 8 141 Power Converter Replacement Suburban 8 142 Battery Equalizer Bracket Replacement Pickup 8 143 Battery Equalizer Replacement Tahoe 8 144 Battery Equalizer Replacement Suburban 8 145 Power Converter Equalizer Bracket Replacement 8 146 Power Converter Equalizer Bracket Replacement Suburban 8 147 Description and Operation 8 149 Interior 8 149 Body Rear 8 150 Specifications eese 8 150 2001 02 LSSV Truck Repair Instructions 8 151 License Plate Bracket Replacement 8 151 Cargo Cover Side Rail and Hinge 8 151 Cargo Cover Front Rail Replacement 8 153 Cargo Cover Rear End Rail Replacement 8 154 Cargo Cover Strut 8 155 Cargo Cover Top Bows Replacement 8 156 Cargo Cover 8 157 Fiberglass Top Replacement 8 157 Cargo Tie Down Eye Replacement 8 158 Cargo Cover Stowage Replacement 8 159 Desc
75. SV Truck ical 6 5 Electr sueis s Buum SWeISKS uonnquijsig Soneueuos punog uonnquisiq En 1 suiejs s 2018 1 uognquisiq uonounr 9josuo pue Jeueg jueuuejsu ul Jejsn o 32019 uonounrf 1 L VOL esn4 12019 1 LYVLS NNY Ul 10H 80 3009 uonounr suejs As BULIM ui soneuleuos uognquisig uonnqiusiq aS pios 101034 JojenBey JoyeinBay 1 1 pilos Mn io 2059 uonounr 5 O10 6701 18 0019 00 2 6701 NYS 92 0 2 89 A SL 2 255812 Joyeotpu Sio Ana 2 euiBu3 BuiBueu pue 2001 02 LSSV Truck 6 6 Engine Electrical LHWX 18 tewereks BULIM si sogeuieuos pte uonnquisiq i Un 1 eis f i S0 88 1 sues Buin Apog 1 ul soneueuos 300191 uonnquisiq uonounrf i pue Jeueg jueuuejsu soneuieuos 2945110 jueunuisu jueuunujsu 69 rus
76. Shafts 4 3 Rear Drive Axle 4 12 Repair 4 3 Repair Instructions 4 12 Wheel Drive Shafts Boot Cover Replacement 4 3 Rear Axle Vent Tube Filter Replacement 4 12 Description and Operation 4 8 Description and Operation 4 13 Wheel Drive Shaft Boot Covers 4 8 Rear Axle Vent Tube Filter Description 4 13 Special Tools and Equipment 4 9 Transfer Case 4 14 Front Drive 4 10 Repair Instructions eerte 4 14 Repair Instructions esses 4 10 Transmission Transfer Case Vent Tube Front Axle Vent Tube Filter Replacement 4 10 Filter 4 14 Description and Operation 4 11 Description and Operation 4 15 Front Axle Vent Tube Filter Description 4 11 Transfer Case Vent Tube Filter Description 4 15 2001 02 LSSV Truck 4 2 Table of Contents Driveline Axle BLANK 2001 02 LSSV Truck Driveline Axle Wheel Drive Shafts 4 3 Wheel Drive Shafts Repair Instructions Wheel
77. aig Ave uonounf uonnqujsig J9Mod Jezijenb3 jexeeug ACL 4oojg ANIL uonounf 0 2001 02 LSSV Truck Body and Accessories 8 6 Wirin youms auas 8 ynoyoe g em b dwe7 ynoyorig _ k 91207 28 9629 8 NYO 8 6 ANd OLL6 ANd 3 6 ANd NYO 0 L ANd OL pog 401g 5 4 Aejay pue 2001 02 LSSV Truck 8 7 irin Body and Accessories uognquisiq LSL 18 80 LSL 1880 g LSL X8 80 4 du d due Que soyen PS duiejpeeH sayen PPS ynoyoelg _7 jnoxyoe g _ 7 3nox2e g uonnquisiq punog uonnqiisiq 051 188 0 90S 07 29200 3 p ou YOUMS 1 10000 i jnoxoel g 2001 02 LSSV Truck Body and Accessories 8 8 Wirin uonnqiasia uonnquisiq uonnquisig EH punouc punog punog punog OSL 8 2 osL ieyeg 1880 3 140 26 u02 i 101291014 PYS i Jojoeuuo
78. air Go to Step 15 Locate and repair the open or high resistance in circuit 901 Did you complete the repair Go to Step 15 Connect a test lamp between cavity 85 and ground Does the test lamp illuminate Go to Step 10 Go to Step 9 Locate and repair the open or high resistance in circuit 901 Did you find and correct the condition Go to Step 15 Go to Converter Inoperative 10 Connect a test lamp between cavity 87 of the voltmeter relay and ground Does the test lamp illuminate Go to Step 11 Go to Step 14 11 Connect a test lamp between cavity and ground Does the test lamp illuminate Go to Step 13 Go to Step 12 12 Replace the voltmeter relay Did you complete the replacement Go to Step 15 13 Locate or repair the open or high resistance in circuit 150 Did you complete the repair Go to Step 15 14 Locate and repair the open or high resistance in circuit 39 Did you complete the repair Go to Step 15 15 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 2001 02 LSSV Truck Engine Engine Electrical 6 31 Repair Instructions Voltage Regulator Test Tools Required e Digital Voltmeter 5 Amp 24V Load e 12V 20 Amp power Supply e Test jumpers or cables Note 24V load may use two 12V automotive head lamps wired in series for this loa
79. applies voltage to pin F of the power converter protector relay located on the upper left hand side of the bulkhead The power converter protector relay coil is connected to pin F and to pin E The CKT 150 BLK wiring from pin E provides a ground path to ground G105 and the power converter protector relay coil is energized When the power converter protector relay coil is energized contacts are closed to apply voltage to the starter solenoid The CKT 900 RED wire from the LH battery to pin C of the power converter protector relay provides voltage which is sent through the CKT 6 PPL wire connected at the power converter protector 2001 02 LSSV Truck relay pin D to starter solenoid terminal S This provides voltage to the hold in winding and the pull in winding of the solenoid Both solenoid windings are energized The circuit through the pull in winding is completed to ground through the starter motor The windings work together magnetically to pull in and hold the plunger The plunger moves the shift lever This action causes the starter drive assembly to rotate as it engages the flywheel ring gear on the engine At the same time the plunger also closes the solenoid switch contacts in the starter solenoid Full battery voltage is supplied directly to the starter motor and it cranks the engine As soon as the solenoid switch contacts close voltage is no longer supplied through the pull in windings since battery voltage is suppli
80. asher and nut 5 6 Remove the front clevis tie down support 4 e 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 59 70 Ib ft 3 Install the front bumper Refer to Front Bumper Replacement Utility 2001 02 LSSV Truck 8 106 5 Body and Accessories HMAN ED 2 2 2001 02 LSSV Truck 4 5 Install the front clevis tie downs 2 Refer to Clevis Tie Down Replacement Front Install engine shield Bumper Replacement Rear Factory Hitch Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 2 Disconnect the negative battery cable of the right battery and the 12V and 24V cables of the left battery Disconnect the blackout marker lamps by depressing the tab releases 2 and remove the ground 1 from the mounting stud Disconnect the trailer lamp connectors by depressing the tab releases Remove the pintle tow hook Refer to Pintle Hook Replacement Remove upper and lower step pads Remove bolts 1 attaching bumper to receiver Body and Accessories Bumpers 8 107 7 Remove the bolts wash
81. ate in Blackout B O Mode 8 68 Park Lamps Operate in Blackout B O Mode 8 73 Stoplamps 8 70 Signals Operate in Blackout B O Mode 8 75 Repair Headlamp Bulb Replacement Blackout 8 76 Headlamp Replacement Blackout B O 8 76 IP Compartment Lamp Replacement Voltmeter 8 80 Marker Lamp Replacement Front Blackout 8 77 Marker Lamp Replacement Rear Blackout 8 78 SCHEMALICS 8 40 Specifications Fastener Tightening Specifications 8 40 Maintenance Owner Checks and Services 0 7 Periodic Maintenance Inspection 0 7 Marker Lamp Repair Marker Lamp Replacement Front Blackout 2 8 77 Marker Lamp Replacement Rear Blackout 8 78 Paint Coatings Exterior and Interior Colors 8 161 Pintle Hook Repair 2001 02 LSSV Truck 4 Pintle Hook 8 114 Power and Grounding Component Views 8 13 Components erede 8 13 Connector End 8 25 Power Converter Repair Power Converter
82. ately The TURM contains information on automatic and manual transmissions and transaxles including the fluid flow and circuit description information The technicians who understand the material in this manual and in the appropriate Dealer Service Bulletins better service the vehicle owners When this manual refers to a brand name a part number or a specific tool you may use an equivalent product in place of the recommended item All information illustrations and specifications in this manual are based on the latest product information available at the time of publication approval General Motors reserves the right to make changes at any time without notice Published by GM DEFENSE MILITARY TRUCKS General Motors Corporation Troy Michigan 48083 92001 GENERAL MOTORS CORPORATION ALL RIGHTS RESERVED The information cutoff date is February 15 2002 LITHO IN U S A PART NO TXO 17817 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 Reporting Errors and Suggestions If you find an error with this GM service manual supplement or if you have a suggestion about this GM service manual supplement we want to hear from you When calling be prepared with the fo
83. autions and Notices 3 Install the end gate rail over the four rivnuts with four bolts Tighten Tighten the four bolts to 8 N m 6 Ib ft 4 Install the cargo cover to the rear end as needed Refer to Cargo Cover Replacement Body and Accessories Body Rear End 8 155 Cargo Cover Strut Replacement Removal Procedure 1 Remove the cargo cover and top bows Refer to Cargo Cover Replacement and Cargo Cover Top Bows Replacement 2 Remove the three front strut bolts holding the three side struts to the hinge bracket 3 Remove the six nylock nuts 4 Remove the three side struts with the six plastic bushings Replace if damaged Installation Procedure 1 Install the six plastic bushings one to the inside and one to the outside of the base hole of each side strut 2 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 3 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 N m 4 Ib ft 5 Install the cargo cover and top bows Refer to Cargo Cover Replacement and Cargo Cover Top Bows Replacement 2001 02
84. ay Pin B 1398 Ignition 1 Voltage Out ud WHT B 1398 Turn Signal Relay Pin BLK 30 Inline Harness Connector C191 Connector Part 12015791 Information e 1 Way F Weather Pack BLK Wire Circuit No Function Pin Color A RED 912A Power to Relay Module 2001 02 LSSV Truck Connector Part e 12010996 Information 1 Way M Weather Pack BLK Wire Circuit No Function Pin Color A ORN 912A Power to Relay Module Body and Accessories Wiring 8 31 Junction Block Body C241 Connector Part 12193930 Information 6 Way F MIP Series 280 Series BLK Wire Circuit No Function Pin Color A EM Not Used B 2r _ Not Used C MD i Not Used D ORN 40A Service Lamp Switch Power E Zu mE Not Used Not Used 2001 02 LSSV Truck 8 32 Wiring Body and Accessories 2001 02 LSSV Truck Repair Instructions Auxiliary Lamp Harness Replacement Front Removal Procedure 1 Remove the radiator grille Refer to Radiator Grille Replacement in Exterior Trim 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 Remove the negative cable of the right battery and the 12V and 24V cables of the left battery 5 Remove the connector from the right hand blackout marker lamp 6 a
85. ce lamp switch 4 2 Connect test lamp between CKT 913 WHT cavity D wire and ground Does the test light illuminate Go to Step 6 Go to Step 5 5 Locate and repair the open or high resistance in circuit 913 Did you correct the condition Go to Step 11 Using a fused jumper connect cavity D to cavity F of the 6 blackout service lamp switch connector Do the brake lamps illuminate Go to Step 7 Go to Step 8 Replace blackout service lamp switch Did you complete the replacement Go to Step 11 m Connect a test lamp between terminal A of the rear B O stop 8 lamp and ground Did the test lamp illuminate Go to Step 10 Go to Step 9 Locate and repair the open or high resistance in circuit 902 Did you correct the condition Go to Step 11 S T Replace the blackout stop lamp s Did you complete the replacement Go to Step 11 ES Operate the system in order to the repair Did you correct the condition System OK Go to Step 2 Blackout Marker Lamps Inoperative Step Action Yes No Schematic Reference Lighting Systems Schematics 4 Did you review Blackout B O Lighting Description and Go to Description Operation Go to Step 2 and Operation Inspect the fuse s check for corroded inline connectors check for broken or partially broken wires inside insulation 2 and for properly installed aftermarket equipment Did you find the condition Go to Step 3 Go to Step 4 Make necessary repairs Did you complete the repairs Go to Step
86. cover onto the trim panel Notice Refer to Fastener Notice in Cautions and Notices 3 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 13 Ib ft 24 Voltmeter Relay Replacement Suburban 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 left trim panel Refer to Trim Panel Replacement Rear quarter utility left in the 2001 02 C K Truck Service Manual 3 Remove the voltmeter relay 2 from the connector 3 22 2 FR Fay Ye ve Y eh AN 629 2001 02 LSSV Truck 8 136 Interior Trim Body and Accessorie AES SEE ER AS LAT 41 lt 3 2001 02 LSSV Truck 1 rm lt Installation Procedure 1 Install the voltmeter relay 2 into the connector 3 2 Install the left trim panel Refer to Trim Panel Replacement Rear quarter utility left in the 2001 02 C K Truck Service Manual Notice Refer to Fastener Notice in Cautions and Notices 3 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 N m 13 Ib ft Contactor Replacement Pickup Models Removal Procedure Caution Refer to Battery
87. ct Caution in Cautions and Notices 1 Disconnect the negative battery cable of the right battery and the 12V and 24V cables of the left battery 2 Remove the winch Refer to Winch Replacement Pickup Models 3 Remove clevis bolts 1 Remove clevises 4 Remove upper support bolts 3 5 Remove lower mount bolts 2 6 Remove mount on left side right side similar Body and Accessories Body Front End 8 119 Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 1 Place mount on vehicle install bolts 2 and tighten Tighten Tighten mount bolts to 68 N m 50 Ib ft Install upper support bolts 3 and tighten Tighten Tighten support bolts to 68 N m 50 Ib ft Install clevises and bolts 1 Tighten Tighten clevis bolts to 200 148 Ib ft Install winch Refer to Winch Replacement Pickup Models Connect electrical connector for the winch Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cables to 17 N m 13 Ib ft Winch Replacement Pickup Models Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the negative battery cable of the right battery and the 12V and 24V cables of the left battery Remove the two lower bolts 1 2001 02 LSSV Truck 8 120 Body Front 2001 02 LSSV Truck 3
88. cut into the space between the headlamp and the turn signal on both sides The winch mounts permanent and multi mount have been added to both the Pickup models and Tahoe Suburban models Refer to applicable procedures for information or the Owner Manual Supplement for how to use the winch 2001 02 LSSV Truck 8 122 Seats Body and Accessories Seats Specifications Fastener Tightening Specifications Specification Application Metric English Seat Bolts 88 65 Ib ft 2001 02 LSSV Truck Body and Accessories Seats 8 123 Repair Instructions Seat Replacement Troop Pickup Models Removal Procedure Notice Note the clamp and stud arrangement for installation later 1 Remove the two 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 two 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 two bolts screws and nuts to the end of the rail Tighten Tighten the bolts to 88 65 Ib ft
89. d 1 Remove the voltage power converter voltage regulator from the vehicle Refer to Power Converter Replacement Tahoe or Power Converter Replacement Suburban in Interior Trim 2 Remove the fuses and test the unit with an ohmmeter Replace any faulty fuses 3 Connect the GND terminal of the unit to the 12V battery ground or a power supply ground Notice The power supply must be set to 12 6V with the power turned ON A small spark may result 4 Connect the 12V terminal of the unit to the 12V battery positive connection or to a power supply positive connection 5 Connect the 24V terminal of unit to one a 5 amp 24V load Connect the opposite of the load to the GND A useful 5 amp 24V load can be built by connecting two 5 amp 12V loads in series Example Connect two 12V headlamps in series 6 Connect the negative terminal of a Digital voltmeter to the 24V terminal of the unit under test Set the meter to the 24V terminal of the unit under test Set the meter to 200VDC and turn it on The meter should read between 11 13V If two 12V series headlamps are being used for the test load the lamps should glow at one half intensity If there is no voltage output or if the unit is putting out 24V check the connections If the connections are accurate return the unit to the manufacturer Sure Power for evaluation 7 Connect IGN terminal of the unit to the 12V terminal using a jumper wire This turns the unit ON
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91. e Install new foam tape to bed rails With the aid of an assistant place the top on the bed rails Install bolts 1 and tighten Connect electrical connection for light if equipped Cargo Tie Down Eye Replacement Removal Procedure 1 Remove the large washer small large washer combination and a bolt depending on the order of arrangement 2 Remove the damaged cargo eye s from the pickup box Installation Procedure 1 Install the cargo eye s in the mounting hole s Notice Refer to Fastener Notice in Cautions and Notices 2 Install the reinforced anchor bolt assembly and tighten Tighten Tighten the bolt assemblies to 47 65 35 48 Ib ft 2001 02 LSSV Truck Body and Accessories Body Rear End 8 159 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 2001 02 LSSV Truck 8 160 Body Rear Body and Accessories Description and Operation Body Rear End The features described here are exclusive to the pickup cargo vehicle The pickup or cargo vehicle is equipped with several military options including a cargo cover troop seats left and right tie down eyes a
92. ecting the auxiliary harness Body and Accessories Wiring 8 33 7 Install connector 4 and the ground to blackout headlamp mounting stud Notice Refer to Fastener Notice in Cautions and Notices 8 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 13 Ib ft 9 Install the filler panel 10 Install the auxiliary harness connections to the original harness 11 Install the radiator grille Refer to Radiator Grille Replacement in Exterior Trim Auxiliary Lamp Extension Harness Replacement Rear 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 cables of the left battery 2 Access the auxiliary rear lamp extension harness from the engine compartment at the left side of the bulkhead 3 Remove the connector 3 from the IP auxiliary harness and tie wrap connecting to the forward lamp harness Caution Refer to Vehicle Lifting Caution in Cautions and Notices 4 Raise and support the vehicle on a hoist and trace the auxiliary rear lamp harness extension along the path of the existing harness and vehicle frame 5 Remove the connector to the rear lamp harness 2001 02 LSSV Truck 8 34 Wirin Body and Accessories 2001 02 LSSV Truck Installation Procedure 1 Install the connector to the rear
93. ed to both ends of the windings The hold in winding remains energized and its magnetic field is strong enough to hold the plunger shift lever and drive assembly solenoid switch contacts in place to continue cranking the engine When the ignition switch is released from the start position battery voltage is removed from the CKT 6 PPL wire and the junction of the two windings Voltage is supplied from the motor contacts through the voltage supplied to the pull in windings However the voltage supplied to the pull in winding is now opposing the voltage supplied when the winding was first energized The magnetic fields of the pull in and hold in windings now oppose one another This action of the windings with the help of the return spring causes the starter drive assembly to disengage and solenoid switch contacts to open simultaneously As soon as the contacts open the starter circuit is turned off Charging The generator provides voltage to operate the vehicle s electrical system and to charge its batteries A magnetic field is created when current flows through the rotor This field rotates as the rotor is driven by the engine creating an AC voltage in the stator windings The AC voltage is converted to DC by the bridge rectifier and is supplied to the electrical system at the battery terminals The RH and LH batteries are wired in series with the LH battery providing 24V to the starter circuit The RH battery supplies splices off
94. eed transfer case The vehicles have a pintle hook with a max trailer weight on highway of 8 700 Ibs 3946 kg Payload capacity is 1 532 Ibs 696 kg varies with equipment The Suburban vehicle is equipped with a 6 0L gasoline engine with a 4 speed 4L80 E automatic transmission and 2 speed transfer case The vehicles have a pintle hook with a max trailer weight on highway of 10 000 lbs 4536 kg Payload capacity is 2 840 Ibs 1291kg varies with equipment 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 lighting A slave receptacle is mounted on the front of the vehicles protected by a radiator brush guard The pickup has a cargo cover and troop seating for up to eight or a hard cap with opening windows all pickup vehicles have cargo hooks mounted on the bed floor A specially upgraded electrical system can handle 24V communications equipment and charging of the 24V batteries 2001 02 LSSV Truck General Information General Information General Information 0 5 Military Equipment Options 2001 02 Commercial Utility Cargo Vehicle LSSV Specifications Options Your vehicle may be equipped with any combination of options Description 12V 24V Power Converter Blackout Lighting NATO Slave Start Brush Guard Front Clevis Tie Downs Rear Clevis Tie Downs Pintle Hook
95. emove the plate Body and Accessories Interior Trim 8 131 Installation Procedure 1 Install the plate to the original holes by aligning Install the new rivets Weapons Support Replacement Lower Removal Procedure 1 Remove the two 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 two bolts 1 holding the support to the floor tighten Tighten Tighten the two bolts to 8 N m 6 Ib ft 2001 02 LSSV Truck 8 132 Interior Trim Body and Accessories 2001 02 LSSV Truck Weapons Mount Replacement Upper Removal Procedure 1 Remove the bolts 1 holding the upper mount to the inner body 2 Remove the upper weapons mount 2 Installation Procedure 1 Install the upper weapons mount assembly 2 by aligning to the body side inner upper panel Notice Refer to Fastener Notice in Cautions and Notices 2 Install the bolts 1 to the assembly Tighten Tighten the bolts to 8 N m 6 Ib ft Weapons Mount Replacement Floor Mount Removal Procedure 1 Remove bolts securing weapons mount to the floor 2 Remove weapons mount 1 from vehicle Body and Accessories Installation Procedure 1 Install weapons mount 1 on floor aligning fastener holes Notice Refer to Fastener Notice in Cautions and Notices
96. ened Tighten Tighten converter connections to 12 110 Ib in 2 Install converter 2 in bracket and tighten bolts 1 Important Verify that the wiring is not pinched and that the converter terminals are not touching the metal bracket 3 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten the battery cable connections to 17 13 Ib ft 2001 02 LSSV Truck 8 142 Interior Trim Body and Accessories 2001 02 LSSV Truck Power Converter Replacement Suburban Removal Procedure Caution Refer to Battery Disconnect Cautions 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 left trim panel Refer to Trim Panel Replacement Rear Quarter utility left in the 2001 02 C K Truck Service Manual 3 Remove cover 1 to gain access to wiring connections 4 Remove wiring connections from top of converter Note removal position for installation 5 Remove bolts 2 and brace 3 left side shown right is similar 6 Remove power converter from vehicle Installation Procedure 1 Install power converter in vehicle 2 Install brace 3 and bolts 2 Tighten 3 Install wiring to connections on converter in the same position as removed 4 Install cover 1 on power converter Body and Accessories Interior Trim 8 143 5 Install the left trim pa
97. ent Rear 8 34 Trailer Wiring Harness Replacement 8 35 Winch Connector Harness Replacement sep EE 8 36 Winch Connector Harness Replacement rp eth oa 8 37 Relay Mounting Bracket Replacement 8 37 Description and Operation 8 39 Wiring 8 39 Lighting Systems 8 40 8 40 Schematic and Routing Diagrams 8 40 Component 8 54 Lighting Systems Component Views 8 54 Connector End Views eene 8 63 Lighting Systems Connector End Views 8 63 Diagnostic Information and Procedures 8 66 Symptom List ecrire eet tentes 8 66 Repair 2 8 76 Headlamp Replacement Blackout 8 76 Headlamp Bulb Replacement Blackout B O 8 76 Marker Lamp Replacement Front Blackout 8 77 Marker Lamp Replacement Rear Blackout 8 78 Compartment Lamp Replacement Voltmeter tee 8 80 Description and Operation 8 81 Black
98. ent 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 cables of the left battery 2 Remove the left fender upper brace 3 Remove top cover 2 4 Remove the electrical center cover assemble by lifting the cover 3 outwards to clear the tabs 2001 02 LSSV Truck 8 38 Wirin Body and Accessories 2001 02 LSSV Truck 5 Drill out the rivets 2 and remove bracket 1 Installation Procedure 1 Rivet the bracket 1 to the electrical center cover Setthe electrical center block in its resting position till the tabs 3 lock into place Install the lower part of the cover 1 Install the upper cover 2 Install the fender upper brace Notice Refer to Fastener Notice in Cautions and Notices 6 Install the 4 fender upper brace bolts Tighten Tighten the 4 retaining bolts to 25 N m 18 Ib ft Install the negative battery cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 N m 13 Ib ft Body and Accessories Wiring 8 39 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 blackout lighting the slave receptacle the power converter voltage regulator and
99. ers and nuts holding the rear bumper to the bumper braces 8 Remove the bolts washers and nuts holding the rear bumper to the frame 2 9 Remove the rear bumper 1 Installation Procedure 1 Install the rear bumper 1 loosely to the frame brackets with the bolts washers and nuts 2 2 Install the rear bumper loosely to the bumper braces with the bolts washers and bolts 3 Install bolts 1 attaching bumper to receiver 4 Connect the trailer lamp connectors 2001 02 LSSV Truck 8 108 5 Body and Accessories 5 Connect the blackout marker lamp connectors 2 and the ground leads 1 from mounting stud 5 3 Notice Refer to Fastener Notice in Cautions and Notices 6 Finish installing all attaching hardware Tighten Tighten the frame bracket nuts to 80 100 59 74 Ib ft Tighten the four brace nuts to 80 100 59 74 Ib ft 7 Install the upper and lower step pads 8 Connect the 12V and 24V cables of the left battery and the negative cable of the right battery Tighten Tighten battery cable connections to 17 N m 13 Ib ft 9 Install the Pintle tow hook Refer to Pintle Hook Replacement 2001 02 LSSV Truck Body and Accessories Bumpers 8 109 Bumper Replacement Rear Military Hitch Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the negative battery cable of the right battery and the 12V and 24V cables o
100. es to the circuit breaker and remove wires Note Note location of wires for reassembly 3 Remove the two bolts 2 holding the 12V 3 or 24V 4 circuit breaker to the fender mount 4 Remove the 12V 1 or 24V 2 circuit breaker 2001 02 LSSV Truck 6 38 Engine Electrical Engine Installation Procedure 1 Install the 12V 1 or 24V 2 circuit breaker 2 Install the 12V 3 or 24V 4 circuit breaker to the fender mount with the two bolts 2 Note Install 24V circuit breaker with auxiliary contact up 3 Install the wires to the circuit breaker with the two nuts 1 Notice Refer to Fastener Notice in Cautions and Notices 4 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cables to 17 13 Ib ft 2001 02 LSSV Truck Engine Engine Electrical 6 39 Circuit Breaker Bracket Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Remove the negative battery cable of the right and the 12V and 24V cables of the left battery 2 Remove the circuit breakers Refer to Circuit Breaker Replacement 12V or 24V 3 Remove bolts 1 and nuts 4 attaching bracket 3 to fender cowl support 2 Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 1 Install bracket 3 to fender cowl 2 and tighten bolts 1 and nuts 4 Tighten Tighten bracket bo
101. esult in a buildup of debris mud ice etc on the lower control arm The purpose of this protective device is to sweep as much debris as possible from the lower control arm This protective device WILL during its useful life take on a ragged appearance while still adequately protecting the drive axle seal The device is functioning as long as the Kevlar fabric continues to sweep debris from the lower control arm 2001 02 LSSV Truck Driveline Axle Driveline Axle Special Tools and Equipment Illustration Tool Number Description 6097 J 41187 Band it Type Tool Wheel Drive Shafts 4 9 2001 02 LSSV Truck 4 10 Front Drive Axle Front Drive Axle 2001 02 LSSV Truck Driveline Axle Repair Instructions Front Axle Vent Tube Filter Replacement Removal Procedure 1 Remove the clamps 2 holding the filter 1 to the hoses 2 Remove the filter 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 Install the hose clamps 2 and tighten 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 w
102. ew Blackout B O Lighting Description and Go to Description Operation Go to Step 2 and Operation 1 Place the blackout service lamp switch in the blackout mode 2 2 Connecta test lamp at cavity C of the blackout switch and ground Does the test light illuminate Go to Step 3 Go to Step 4 Replace the blackout service lamp switch Did you complete the replacement Go to Step 9 ER Connect a test lamp to cavity A3 of the relay block and 4 ground Does the test lamp illuminate Go to Step 5 Go to Step 6 Locate and repair the short to voltage on circuit 912 RED gt Did you complete the repair Go to Step 9 4 2001 02 LSSV Truck Body and Accessories Lighting Systems 8 75 CTSY Lamps Operate in Blackout B O Mode cont d Step Action Yes No Remove the CTSY interrupt relay from the relay module Are the CTSY lamps illuminated Go to Step 8 Go to Step 7 Replace the CTSY interrupt relay Did you complete the replacement Go to Step 9 m Locate and repair the short to voltage on circuit 40B ORN Did you complete the repair Go to Step 9 2n Operate the system in order to verify the repair i 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
103. f 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 lamps before beginning to operate the vehicle each time Maintenance and Lubrication 0 7 Inspect the axle vent tube filter for blockages every six months and more often when difficult off road conditions are encountered Replace as needed Refer to the Front or Rear Axle Vent Tube Filter Replacement procedure in Driveline Axle Inspect the transmission 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 Transmission Transfer Case Vent Tube Filter Replacement Procedure in Driveline Axle Winch Maintenance Refer to Warn Industries Operator s Manual found in glove compartment 2001 02 LSSV Truck Suspension Table of Contents 3 1 Section 3 Suspension Front Suspension 3 3 Shock Absorber Replacement 3 8 Specifications 3 3 Description and Operation 3 9 Repair Instructions c ssecsssesseeseeseeeeeeseeeseeees 3 4 Rear Shock Absorber Description 3 9 Shock Absorber 3 4 Tires and Wheels
104. f the left battery 2 Disconnect the blackout marker lamps by depressing the tab releases 2 and remove the ground 1 from mounting stud 3 Disconnect the trailer lamp connectors 2 3 by depressing the tab releases 4 Remove the clevis tie down Refer to Clevis Tie Down 0 Replacement Rear 5 Remove pintle hook from the receiver oS em 23 4 o d 10252 2001 02 LSSV Truck 8 110 Bumpers Body and Accessories 6 Remove the lower step pad 7 Remove lower bolts attaching bumper to receiver 8 Remove the bolts and nuts holding the rear bumper to the brace s at the lower attaching points 9 Remove the bolts and nuts holding the rear bumper to the brace s at the upper attaching points 10 Remove the bolts washers and nuts holding the rear bumper to the frame rail 11 Remove the rear bumper 1 Installation Procedure 1 Install the rear bumper 1 loosely to the frame rail with the bolts and the washers and nuts 2 Install the rear bumper loosely to the brace s at the upper attaching points with the bolts and nuts 3 Install the rear bumper loosely to the brace s at the lower attaching points with the bolts and nuts 4 Connect the trailer lamp connectors 2 3 2001 02 LSSV Truck B ody and Accessories 5 Connect the blackout marker lamp connector 2 the ground leads 1 from the mounting bracket Notice Refer to Fastener Notice in Cautions and No
105. ff the stud 6 Remove the auxiliary wiring harness lead by releasing the connector tab 1 7 Remove the blackout lamp assembly from the mounting bracket Installation Procedure 1 Install the blackout lamp assembly to the mounting bracket 2 Install 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 7 Ib ft 5 Install the radiator grille 6 Install upper grille baffle 7 Install the radiator brush guard Refer to Radiator Brush Guard Replacement in Bumpers Headlamp Bulb Replacement Blackout B O Removal Procedure 1 Remove the screws 1 holding the lens cap to the assembly 2 Remove the lens cap and O ring 3 Remove the bulb Important Use a standard 1973 bulb for replacement Body and Accessories Lighting Systems 8 77 Installation Procedure 1 Install the new bulb in the assembly Notice The O ring installation must be a proper fit 2 Install the O ring with the lens cover 3 Install the three screws 1 to the assembly Marker Lamp Replacement Front Blackout B O 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 cables of the left battery 2 Remove bolt 1 on brush guard a
106. front blackout marker lamps are mounted in the grille of both vehicles The rear blackout marker lamps are arranged in the same relative positions on each of the rear bumpers The voltmeter lamp provides illumination to the voltmeter mounted in the dash The service blackout lamp switches mounted at the lower center dash control blackout lamp and standard lamp functions A pair of toggles operates these switches The blackout 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 amp auxiliary lamps When the switch is moved to Blackout ON only the blackout lighting will work which includes the blackout markers front and rear and the blackout headlamp Within the rear marker lamps are separate color markers Yellow will illuminate for the brakes and red will illuminate for drive mode The front markers illuminate in yellow The horn is inoperative while the blackout toggle is in the ON position All warning lamps in the IP remain functional regardless of the toggle position If the vehicle is parked for over 24 hours place the service switch in All OFF To operate the blackout drive light switch pull it out and left to the ON position this will activate the front blackout headlamp This will occur provided the
107. ightening 8 162 Front Drive Axle Description Front Axle Vent Tube Filter 4 11 Repair Front Axle Vent Tube Filter Replacement 4 10 Front Suspension Description Front Shock Absorber 3 6 Repair Shock Absorber Replacement 3 4 Specifications Fastener Tightening 3 3 Government Vehicle Data Plate Replacement 8 130 H Headlamp Repair Headlamp Bulb Replacement Blackout B O e te mens 8 76 Headlamp Replacement Blackout B O 8 76 Horns Description Horn with Blackout B O Control Circuit ODperatlon 2 5 8 94 Diagnosis Horns 8 91 Horns Operate in Blackout Mode 8 93 Schematics 2 td arte ens 8 89 INDEX Identification Vehicle 0 3 Instrument Panel Gages and Console Description Instrument Panel and Gages Description 8 88 Repair Blackout Switch Replacement 8 86 Voltmeter 8 85 Voltmeter Blackout B O Switch Panel 2 222221 8 85 Specifications Fastener 8 84 Interior Trim Descrip
108. ijenb3 10119Au02 2001 02 LSSV Truck Engine Engine Electrical 6 9 Component Locator Starting and Charging Component Views Voltmeter and Lamp Legend 1 Voltmeter Bracket 4 Voltmeter 24V 2 Mounting Bracket 5 Voltmeter Illumination Bulb 3 Voltmeter Connector 6 Harness Connector 2001 02 LSSV Truck 6 10 Engine Electrical Engine Blackout B O Lamp Switches Legend 1 Component Connector 4 Mounting Bracket 2 B O Control Switch 5 B O Drive Lamp Switch 3 Switch Position Label 6 Component Connector 2001 02 LSSV Truck Engine Engine Electrical 6 11 Power Converter Harness Routing Body Side View Utility Legend 1 Harness to IP Convenience Center 4 Wiring Harness to Voltmeter 2 Wiring Harness to Circuit Breaker 5 Body Side Panel 3 Grommet 2001 02 LSSV Truck 6 12 Engine Electrical Engine Power Converter Harness Routing Rear Lamp Utility Legend 1 Power Converter Harness 3 Rear Lamp Extension Harness 2 Frame 2001 02 LSSV Truck Engine Engine Electrical 6 13 Power Converter Harness Routing Pickup Legend 1 Wiring Harness to Voltmeter 4 Jumper Wiring Harness 2 Wiring Harness to Circuit Breaker 5 Wiring Harness to Relay 3 Wiring Harness to Contactor 2001 02 LSSV Truck 6 14 Engine Electrical Engine Power Converter Legend 1 Ground Connection 4 Fuse Link Covers 2 12 Volt Connection 5 Ignition Connec
109. ion Instrument Panel and Gages Description The instrument panel has been modified by removal of the lower panel beneath the ashtray A bracket mounted in this space houses the blackout lighting switches and 24V meter The instrument panel houses auxiliary harnesses as well as standard indicators Some modification has been made to the instrument panel to accommodate auxiliary harness connections and convenience fuse centers 2001 02 LSSV Truck Body and Accessories Horns 8 89 Horns Schematic and Routing Diagrams 2001 02 LSSV Truck Body and Accessories 8 90 Horns 091 SE O UJOH ZZA 622 NHO 60 9919 9 6 2 NYS 8 0 WO r T 1 suejs s OJjUOD Aeey soneueuog uonnguisiq 091 S O 82 418560 6ZEL NH9 S 0 8 0 suiajs g soneueuos uognquisiq ut 1 sogeuieuos 4 vosi 1 880 yoo g 92 6 uonounf iiv 1e OH 2 8 418 SE 2001 02 LSSV Truck Body and Accessories Horns 8 91 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 Mode Horns Inoperative Step Ac
110. ionary 3 Remove the wiring from the contactor 1 Note the position of wires for installation 4 Remove screws securing contactor to the body ez ES 5 Installation Procedure 1 Install screws securing contactor 1 to the body Notice Refer to Fastener Notice in Cautions and Notices 2 Install wiring to contactor in the same position as removed Notice A back up wrench must be used to hold the bottom nut 9 stationary UNE Tighten Tighten the larger contact terminal nuts to 5 6 Nem 45 55 Ib in Tighten Tighten the smaller coil terminal nuts to 1 2 N m 12 18 Ib in 3 Install the left trim panel Refer to Trim Panel Replacement Rear Quarter utility left in the 2001 02 C K Truck Service Manual 4 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 13 Ib ft 2001 02 LSSV Truck 8 140 Interior Trim Body and Accessories Power Converter Bracket Replacement Pickup Models 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 cables of the left battery 2 Remove cover 1 from power converter 2 3 Remove wiring from power converter terminals Note the removal position of wiring for installation 4 Remove lower bolts 1 from the power converter bracket
111. ipped necessary for off road conditions The replacement procedure is very similar to the procedure for the standard truck 2001 02 LSSV Truck Suspension Rear Suspension 3 7 Rear Suspension Specifications Fastener Tightening Specifications Specification Application Metric English Shock Absorber Nuts 95 70 Ib ft 2001 02 LSSV Truck 3 8 Rear Suspension Suspension 2001 02 LSSV Truck Repair Instructions Shock Absorber Replacement Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices Notice Original equipment shock absorbers serve additionally as suspension drop cutoffs Replacement shock absorbers must have a built in suspension cutoff feature and must not be longer than original shocks when they are fully extended or serious vehicle or component damage could result 1 Raise and support the vehicle 2 Remove the upper shock absorber nut and bolt 3 Remove the lower shock absorber nut and bolt 4 Remove the shock absorber Installation Procedure 1 Install the shock absorber 2 Install the upper shock absorber nut and bolt Notice Refer to Fastener Notice in Cautions and Notices 3 Install the lower shock absorber nut and bolt Tighten Tighten the upper and lower nuts to 95 70 Ib ft 4 Remove the safety stands 5 Lower the vehicle Suspension Rear Suspension 3 9 Description and Operation Rear Shock Absorber Descr
112. iption The suspension features a heavy duty shock absorber package if equipped necessary for off road conditions The replacement procedure is very similar to the procedure for the standard truck 2001 02 LSSV Truck 3 10 Tires and Wheels Suspension Tires and Wheels 2001 02 LSSV Truck Repair Instructions Tire Hoist Shaft Extension Replacement Removal Procedure 1 Remove the spare wheel storage lock cylinder Refer to vehicle 2001 02 C K Truck Owner s Manual 2 Remove the spare tire Refer to Spare Tire Removal in the 2001 02 C K Truck Service Manual 3 Pull the retainer clip and remove the pin 4 Remove the bar Installation Procedure 1 Install the new bar and align 2 Install the retainer clip and pin 3 Install the spare tire Refer to Spare Tire Installation in the 2001 02 C K Truck Service Manual 4 Install the spare wheel storage lock cylinder Refer to vehicle 2001 02 C K Truck Owner s Manual Suspension Tires and Wheels 3 11 Description and Operation Tires and Wheels Spare Wheel Hoist Shaft The hoist shaft may require replacement if damaged On pickup models the spare tire is mounted under the rear end of the pickup On Utility models the spare tire is mounted under the rear of the vehicle Refer to Tire Hoist and Shaft Replacement in the 2001 02 C K Truck Service Manual 2001 02 LSSV Truck Driveline Axle Table of Contents 4 1 Section 4 Driveline Axle Wheel Drive
113. ircuit of the inoperative bulb for high resistance an open or a short to 3 ground Did you find and correct the condition Go to Step 17 Go to Step 5 2001 02 LSSV Truck Body and Accessories Lighting Systems 8 69 Backup Lamps cont d Step Action Yes No 1 Inspect the condition of the backup lamp fuses 2 15 the fuse 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 lamp between connector C1 cavity F Pickup of the junction block rear lamps and ground or C405 cavity F Utility and ground Does the test lamp illuminate Go to Step 7 Go to Step 8 Connect a test lamp between connector C3 cavity B3 and ground Does the test lamp illuminate Go to Step 8 Go to Step 9 Locate and repair the open or high resistance in circuit 1324 Did you complete the repair Go to Step 17 Connect a test lamp between cavity A7 of the interrupt relay and ground Does the test lamp illuminate Go to Step 10 Go to Step 11 10 Locate and repair the open in circuit 839A Did you complete the repair Go to Step 17 11 Connect a test lamp between cavity B9 of the interrupt
114. isconnect 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 radiator grille brush guard Refer to Radiator Grille Brush Guard Replacement 3 Remove the front grille Refer to Radiator Grille Replacement in Exterior Trim 4 Remove the winch mount if equipped Refer to Winch Mount Replacement Pickup Models in Body Front End 2001 02 LSSV Truck 8 102 Bumpers Body and Accessories 2001 02 LSSV Truck 5 Remove the retaining bolts 1 2 from the front bumper 6 Remove the brace bolt 3 from the front bumper 7 Remove the front bumper assembly from the vehicle 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 63 Ib ft Tighten the bracket bolt 2 to 85 Nem 63 Ib ft Tighten the brace bolt 3 to 55 Nem 41 Ib ft 3 Install winch mount if equipped Refer to Winch Mount Replacement Pickup Models in Body Front End 4 Install the front radiator grille 5 Install the radiator grille brush guard Refer to Radiator Grille Brush Guard Replacement 6 Install the negative battery cable of the right battery and the 12V and the 24V cables of the left battery Tighte
115. ith a vented cap at the end and is mounted in the engine compartment next to the left inner wheel housing The filter must be inspected occasionally to see if it needs to be replaced Refer to Periodic Maintenance Inspections in Maintenance Schedule section in 2001 02 LSSV Operator s Manual Supplement Front Drive Axle 4 11 2001 02 LSSV Truck 4 12 Rear Drive Axle Rear Drive Axle 2001 02 LSSV Truck Driveline Axle Repair Instructions Rear Axle Vent Tube Filter Replacement Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices 1 Raise the vehicle and support with safety stands 2 Remove the clamps 2 holding the filter 1 to the hoses 3 Remove the filter 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 Install hose clamps 2 and tighten 2 Remove safety stands and lower vehicle Driveline Axle Description and Operation Rear Axle Vent Tube Filter Description The rear axle is specially equipped with a vent tube filter to protect the axle from contaminants found in the off road environment It is attached to a hose with a vented cap at the end The rear axle vent filter is mounted on the top of the axle housing and the hose is attached to the brake bracket on the driver s side frame rail The fi
116. izer label is located on the side of the equalizer This label includes information on model number serial number and voltage specifications Owner User s Label CUCV IIl Owners Users Information Warranty Repair Any Chevrolet Light Duty Dealer located within the United States Canada or Mexico for assistance Parts obtain a replacement part for your CUCV Contact your hevrolet Dealership They can assist you with identifying obtaining the correct part for your vehicle Unique military parts such as blackout lights grille guard or 24 volt equipment an be obtained only by contacting GM Defense Military rucks See Directory Exterior Paint Information M CUCV Green PPG 402583 lat Brown Camo PPG 26187 lat Black Camo PPG 9677 GM Military Trucks Directory Service Parts 248 680 5070 echnical Support 248 680 2843 ehicle Sales 248 680 5222 10570 The owner user s label is located in the glove compartment and has information pertaining to the vehicle s upfitting Refer to Paint Codes in Paint Coatings for current exterior paint part numbers General Information Maintenance and Lubrication Maintenance Owner Checks and Services If the engine controls instruments or gages do not operate as described in this supplement manual refer to one of the following manuals e 2001 02 C K Truck Owner s Manual e 2001 02 C K Truck Service Manual e 2001 02 Diesel Engine Owner s Manual Supplement I
117. lamp harness 2 Remove supports and lower the vehicle and install the auxiliary rear lamp harness extension along the path of the existing harness and vehicle frame 3 Install the connector 3 to the IP auxiliary harness and tie wrap holding to the forward lamp harness 4 Install the auxiliary rear lamp extension harness to the engine compartment location at the left side of the bulkhead Notice Refer to Fastener Notice in Cautions and Notices 5 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 N m 13 Ib ft Lamp Harness Replacement Rear 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 cables of the left battery 2 Remove the rear lamp harness connector from the left tail lamp connector 3 Remove the ground lead and connector for the left blackout marker lamp 4 Remove the vehicle ground lead bolt washer and harness ground 5 Remove the rear lamp harness connector from the auxiliary rear lamp extension harness 6 Remove the rear lamp harness connector from the rear lamp extension harness 7 Remove the two rear lamp harness connectors 7 8 from the trailer jumper 8 Remove the ground lead nut ground lead and connector from the right blackout marker lamp 9 Remove the rear lamp harness connector from the
118. lation 3 Clean stud threads with steel wool or a wire brush Clean the contact surface of the inside jam nuts 5 4 Disconnect fuse link 6 and disgard 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 74 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 N m 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 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cables to 17 Nem 13 Ib ft Engine Engine Electrical 6 37 Circuit Breaker Replacement 12V or 24V 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 nuts 1 holding the wir
119. llowing information Your Your dealership s name Military organization Your dealership s Military organization s phone number The model year and the vehicle line The publication part number if present The vehicle identification number of the vehicle being worked on The service manual section and page number s Any applicable electronic information element identification numbers A descriptive explanation of your concern The GM service manual phone personnel will respond to your concerns in the following ways By delivering your concern to the manual s author By eliciting a response from the author By supplying you with an answer to your concerns For paper manual users The GM service manual phone personnel will also explain how to send in examples or marked up pages The GM service manual comment telephone numbers do not provide technical assistance For technical assistance contact your regular technical assistance source United States Please call the following number Monday through Friday with your comments 1 248 680 2843 fax number 248 680 5275 United States Owner Operator Vehicle owners or operators are encouraged to address their comments and concerns to the applicable Customer Assistance Center The phone number and address of the Customer Assistance Center are in the Owner s Manual General Motors Defense Military Trucks Contact Information
120. lter must be inspected occasionally to see if it needs to be replaced Refer to Periodic Maintenance Inspections in Maintenance Schedule section in 2001 02 LSSV Operator s Manual Supplement Rear Drive Axle 4 13 2001 02 LSSV Truck 4 14 Transfer Case Transfer Case 2001 02 LSSV Truck Driveline Axle Repair Instructions Transmission Transfer Case Vent Tube Filter Replacement Removal Procedure Caution Refer to Vehicle Lifting Caution in Cautions and Notices 1 Raise the vehicle and support with safety stands 2 Remove the hose and filter assembly from the transmission transfer case by removing the connecting hose clamps Discard the filter 3 Remove the two hose clamps holding the filter to the hose Discard the clamps Installation Procedure Notice The filter flow arrow must point in the direction of the transmission transfer case If replacing the hose the length of the new hose must match the length of the old hose 1 Install the new filter to the two hoses with the two new hose clamps 2 Install the filter assembly with vent cap near the end opposite the transfer case 3 Push the vent cap end between the filler tube pipe and the transmission Push to a vertical exit 4 Secure the vent hose with tie wrap to the nearest electrical harness and the transmission filler tube pipe 5 Remove safety stands and lower vehicle Driveline Axle Description and Operation Transfer Case Vent Tube Filter Descrip
121. lts to 4 6 N m 3 4 5 Ib ft 2 Install circuit breakers Refer to Circuit Breaker Replacement 12V or 24V 3 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cables to 17 N m 13 Ib ft Battery Tray Battery Replacement 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 cables of the left battery 2 Loosen bolts 1 Push up battery tray 2 and remove from frame 3 Unsnap the positive battery cable cover if equipped Remove positive and negative battery cables 5 Remove retainer bolt and remove battery 2001 02 LSSV Truck 6 40 Engine Electrical Engine 2001 02 LSSV Truck Installation Procedure 1 Install battery in tray Notice Refer to Fastener Notice in Cautions and Notices 2 Install battery retainer and tighten bolt Tighten Tighten retainer bolt to 25 N m 18 Ib ft Install positive and negative cables and tighten Tighten Tighten cables to 17 13 Ib ft Snap the positive battery cable cover closed Lift battery tray onto bolts on frame and tighten Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cables to 17 N m 13 Ib ft Battery Booster Slave Junction Block Replacement Removal Procedure
122. matic Reference Lighting Systems Schematics 1 Did you review Blackout B O Lighting Description and Go to Description Operation Go to Step 2 and Operation 2001 02 LSSV Truck 8 74 Lighting Systems Body and Accessories Park Lamps Operate in Blackout B O Mode cont d Step Action Yes No 1 Place the blackout service lamp switch in the blackout mode 2 2 Connecta test lamp at cavity C of the blackout switch and ground Does the test light illuminate Go to Step 3 Go to Step 4 Replace the blackout service lamp switch Did you complete the replacement Go to Step 9 pen Connect a test lamp to cavity C4 of the relay block and 4 ground Does the test lamp illuminate Go to Step 5 Go to Step 6 Locate and repair the short to voltage on circuit 240A 5 ORN BLK Did you complete the repair Go to Step 9 m Remove the park lamp interrupt relay from the relay module Are the park lamps illuminated Go to Step 8 Go to Step 7 Replace the park lamp interrupt relay 4 Did you complete the replacement Go to Step 9 sun Locate and repair the short to voltage on circuit 240A 8 ORN BLK Did you complete the repair Go to Step 9 m Operate the system in order to verify the repair Did you correct the 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 revi
123. ment Suburban 4 Remove the battery equalizer Refer to Battery Equalizer Replacement Suburban 5 Remove bolts 1 securing bracket 2 to vehicle body Right side shown left side similar 2001 02 LSSV Truck 8 148 Interior Trim Body and Accessories Installation Procedure 1 Install bolt 1 securing bracket 2 to the vehicle body Right side shown left side similar 2 Install the battery equalizer Refer to Battery Equalizer Replacement Suburban 3 Install power converter Refer to Power Converter Replacement Suburban 4 Install the left trim panel Refer to Trim Panel Replacement Rear Quarter Utility Left in the 2001 02 C K Truck Service Manual Notice Refer to Fastener Notice in Cautions and Notices 5 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 Nem 13 Ib ft 2001 02 LSSV Truck Body and Accessories Interior Trim 8 149 Description and Operation Interior Description The interior trim options for these vehicles include special weapons supports for the M14 and M16 firearms as well as a modification to the side trim panel in the utility vehicle for the 12V 24V converter and or batter equalizer Refer to the Owner s Manual Supplement for weapon mount operation and use 2001 02 LSSV Truck 8 150 Body Rear Body and Accessories Body Rear End Specifications
124. mer the band flat between the latch tabs Peen the latch tabs over in order to lock the back into position 8 Twist the halfshaft seal cover 1 90 degrees Important Be sure that the inboard tab of the halfshaft seal cover 1 is 180 degrees opposite the outboard tab of the halfshaft seal cover 1 before proceeding 9 Position the outboard end of the halfshaft seal cover 1 over the CV joint 2 flat Wheel Drive Shafts 4 5 2001 02 LSSV Truck 4 6 Wheel Drive Shafts 2001 02 LSSV Truck Driveline Axle Important Tighten the seal cover clamp 1 as tight as possible without deforming the retaining clip Clamps that are not tight enough allow the cover to slide upon the joint This causes shortened service life 10 Use J 41187 in order to tighten the outboard cover clamp 1 11 Rotate J 41187 toward the clip in order to bend the band onto the clip 12 Pull the tool s cutting handle in order to cut off the excess band 13 Hammer the band flat between the latch tabs Peen the latch tabs over in order to lock the band into position Driveline Axle Wheel Drive Shafts 4 7 14 Gather the halfshaft seal cover material at the center Wrap the halfshaft seal cover 1 tightly with the nylon strap 2 provided in the kit 2001 02 LSSV Truck 4 8 Wheel Drive Shafts Description and Operation Wheel Drive Shaft Boot Covers This protective device is intended for off highway usage Off highway usage can r
125. mps The blackout stoplamps receive constant ground through G401 Backup Lights Backup Lamps Circuit of Operation When the ignition switch is in run voltage is applied through the turn bu fuse to the taillamp relay When the blackout service drive switch is placed in service position voltage is applied to the taillamp relay control circuit through the ORN 912 wire The relay contacts are normally closed allowing voltage to the backup lamp switch through the PNK 139 wire With the transmission in reverse voltage is applied to the LH and RH backup lamps which are permanently grounded When voltage is applied to LTGRN 24 wire the backup lamps are on When the blackout service drive switch is placed in blackout position the taillamp relay is deactivated and the backup lamps are inoperative The LTGRN 24 wire also supplies input to the electrochromatic rearview mirror dimming function Connection is also provided for the trailer tow capability Blackout B O Lighting Description This section focuses on the function and service of the blackout headlamp the front and rear blackout marker lamps the service blackout lamp switch and the voltmeter lamp All other lamps are covered in the 2001 02 C K Truck Service Manual As military options the blackout lamps provide a stealthy low illumination alternative to standard lighting systems also available on these vehicles The blackout headlamp is identical on these vehicles The
126. n Tighten battery cable connections to 17 N m 13 Ib ft Body and Accessories Bumpers 8 103 Radiator Grille Brush Guard Replacement Removal Procedure 1 Remove the two bolts 1 washers and nuts holding the brush guard to upper supports 2 Remove three lower fasteners 2 from the bumper 3 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 three fasteners 2 washers and nuts Tighten Tighten the three nuts to 88 N m 65 Ib ft 3 Install the two bolts 1 washers and nut to the upper supports and tighten Tighten Tighten the bolts to 88 65 Ib ft Clevis Tie Down Replacement Front Removal Procedure 1 Remove nut 1 and bolt 3 2 Remove clevis 2 from mount 2001 02 LSSV Truck 8 104 Bumpers Body and Accessories 2001 02 LSSV Truck Installation Procedure 1 Install clevis 2 to the mount Notice Refer to Fastener Notice in Cautions and Notices 2 Install bolt 3 and nut 1 and tighten Notice Clevis must move once torqued Do not over torque Tighten Tighten nut and bolt to 200 N m 148 Ib ft Clevis Tie Down Support Replacement Front Pickup Models Removal Procedure 1 Remove the engine shield 2 Remove the front clevis tie down Refer to Clevis Tie Down Re
127. nd fiberglass top Cargo Cover The cargo cover is a rain resistant canvas top cover supported by bows and struts and attached by rails to the cargo box It can be buttoned down with hooks and snaps or zipped closed It may also be rolled up with straps or folded and stowed while not in use Cargo Cover Cleaning Mildewy areas should be cleaned by scrubbing with a dry brush Never use solvents If necessary to use water to remove dirt it should not be used until the mildew has been removed After removing the mildew examine the fabric and look for deterioration If the canvas has deteriorated replace it 2001 02 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 Owner s Manual Supplement for further details Tie Down Eyes The tie down eyes are metal eyelets bolted into the box bed with reinforced hardware They are used to secure equipment to the box floor and have a maximum vertical resistance rating of 300 kg 660 Ibs and a maximum horizontal resistance rating of 200 kg 450 Ibs Body and Accessories Paint Coatings 8 161 Paint Coatings Paint Codes Exterior and Interior Colors Location Color Fed std 595 B PPG No Green 34094 CA 8211 I 5086 Flat Brown Camo 34094 CA 8211 17036 Flat Black Camo 34094 CA 8211 18007 For specific paint coating details contact PPG Automotive
128. nd ground Does the test lamp illuminate Go to Step 16 Go to Step 17 16 Replace the 24V circuit breaker Did you complete the replacement Go to Step 18 17 Locate and repair the circuit that feeds the 24V circuit breaker Did you complete the repair Go to Step 18 18 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 Voltmeter Inoperative Step Action Value s Yes No Schematic Reference Engine Electrical 1 Did you review the Starting and Charging System Description and Operation Go to Step 2 Go to Description and Operation 2001 02 LSSV Truck 6 30 Engine Electrical Engine Voltmeter Inoperative cont d Step Action Value s Yes No Connect a test lamp between cavity A of the voltmeter and ground Note Vehicle must be running for the following steps Does the test lamp illuminate Go to Step 3 Go to Step 4 Connect a test lamp between cavity B of the voltmeter and ground Does the test lamp illuminate Go to Step 5 Go to Step 6 Connect a test lamp between cavity 86 of the voltmeter relay and ground Does the test lamp illuminate Go to Step 7 Go to Step 8 Locate and repair the open in circuit 150 Did you complete the repair Go to Step 15 Replace the voltmeter Did you complete the rep
129. nd slide out the blackout marker light assembly from grille 3 Remove the harness connector 2 by releasing the connector tab 4 Remove the nut holding the ground lead and stud to the marker mounting bracket 5 Remove the nut holding the lamp stud to the marker mounting bracket 6 Remove the blackout marker lamp assembly 1 2001 02 LSSV Truck 8 78 Lighting Systems 2001 02 LSSV Truck 10344 Body and Accessorie Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 1 Install mounting bracket to blackout marker and lamp assemble 1 Tighten Tighten marker lamp nuts to 2 N m 1 5 Ib ft Install ground lead to blackout marker lamp stud Tighten Tighten ground lead nut to 2 1 5 Ib ft Install harness connector 2 to marker lamp connector Install marker lamp assembly into opening in grille and install bolt 1 to brush guard Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 N m 13 Ib ft Marker Lamp Replacement Rear Blackout B O Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 2 Remove the negative cable of the right battery and the 12V and 24V cables of the left battery Remove the nut 1 from the bracket and remove marker lamp assembly 5 Body and Accessories Lighting Systems
130. nd the left hand blackout marker lamp 5 and the ground nut to the ground lead and all tie wraps connecting the auxiliary harness 6 Remove connector 4 and ground from blackout headlamp mounting stud 7 Trace the auxiliary harness under the washer fluid reservoir and remove the tie wrap along the fender interior 8 Trace the auxiliary harness under the battery tray area and remove the wrap 9 Remove the forward auxiliary harness 2 from the vehicle 10 Remove the tie wraps near the bulkhead and disconnect the forward connector of the auxiliary harness from the auxiliary IP harness connector and tie wrap holding it to the harness connector Installation Procedure 1 Connect the forward connector of the auxiliary harness to the auxiliary IP 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 tie wrap 4 Install the auxiliary battery and tray Make modifications using a drill drill holes to allow the mounting of the tray Refer to Battery Tray Replacement in the 2001 02 C K Truck service manual 5 Install the auxiliary harness under the washer fluid reservoir area and install the tie wrap along the fender interior 6 Install the connector to the right hand blackout marker lamp 6 and the left hand blackout marker lamp 5 and the ground nut to the ground lead and all tie wraps conn
131. nel Refer to Trim Panel Replacement Rear Quarter utility left in the 2001 02 C K Truck Service manual Notice Refer to Fastener Notice in Cautions and Notices 6 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 13 Ib ft Battery Equalizer Bracket Replacement Pickup Models Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Remove the negative cable from the right battery and the 12V and 24V cables of the left battery 2 Remove cover 2 from equalizer and lay aside Note Contactor 3 will remain on the cover 3 Remove the wiring from the equalizer 1 connections Note removal positions for installation 4 Remove lower bolts 3 from bracket 5 Remove upper bolts 1 from bracket and remove from the vehicle 6 Remove bolts 2 securing equalizer 4 to the bracket 2001 02 LSSV Truck 8 144 Interior Trim Body and Accessories Installation Procedure 1 Install equalizer 4 to the bracket and secure with bolts 2 2 Install bracket with equalizer in vehicle 3 Secure bracket with lower bolts 3 and upper bolts 1 Notice Refer to Fastener Notice in Cautions and Notices 4 Install the wiring to the equalizer connections in the same position as removed Tighten Tighten the equalizer connections to 12 N m 110 Ib in 5 Install cover 2 over the end
132. nput provides operating power for the regulator This switch closure allows current to flow which causes the charge warning indicator to light For vehicles with the diesel engine the tachometer input is sensed at pin P of the generator Generator connector cavity A connects to generator pin P to send the pulsing voltage signal to pin 6 of the instrument cluster through the CKT 121 WHT wire The instrument cluster converts the voltage frequency to engine rpm Power Converter Regulator Battery voltage is available at all times through the 24V circuit breaker which is located on the LF fender bracket Voltage is made available through CKT 900 RED to stud A of the power converter regulator When the ignition switch is placed in START the power converter 24V stud A and the ignition stud B provide voltage to the voltmeter relay Stud C of the power converter protector connector The power converter regulator is grounded at G112 and the voltmeter relay is grounded through the power converter regulator The power converter regulator converts 12V to 24V to provide voltage throughout the entire vehicle The power converter is equipped with replaceable fuse links to protect against reverse polarity and output shorts to ground conditions The 24V source is used only in military auxiliary equipment and military radio eqipment Battery Equalizer The primary function of the Battery Equalizer is to maintain battery balance or equalization charge
133. ns Options 0 5 Labels 0 6 2001 02 LSSV Truck 0 2 Table of Contents General Information BLANK 2001 02 LSSV Truck General Information General Information Vehicle Identification The 2001 02 LSSV series military pickup Tahoe Suburban and ambulance models derive from standard commercial vehicles The utility is a 1500 Tahoe and 2500 Suburban based military command vehicles The pickup is a 2500HD or 1 ton based cargo troop carrier The pickup chassis is also used for the ambulance 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 5 mph These limits are met without causing permanent damage or requiring immediate maintenance Base Cargo Troop Carrier Extended Cab General Information 0 3 Tahoe Suburban Crewcab Cargo Troop Carrier 2001 02 LSSV Truck 0 4 General Information Ambulance The pickup vehicles are equipped with a 6 6L Turbo diesel engine with a 5 speed Allison automatic transmission and 2 speed transfer case The vehicles have pintle hooks with a max trailer weight on highway of 12 000 165 5443 kg Payload capacity is 3 200 Ibs 1454 kg for the pickup vehicle The Tahoe vehicle is equipped with a 5 3L gasoline engine with a 4 speed 4L60 E automatic transmission and a 2 sp
134. nverter Refer to Power Converter Replacement Tahoe 3 Remove the Battery Equalizer Refer to Battery Equalizer Replacement Tahoe 4 Remove the Power Converter contactor mounting bolts from bracket 5 Remove the upper bolts 1 and lower bolts 2 6 Remove mounting bracket 4 7 Drill out rivnuts 3 TX 016183 if damaged Body and Accessories Interior Trim 8 147 Installation Procedure 1 Install rivnuts 3 TX 016183 if removed 2 Install mounting bracket 4 and tighten lower mounting bolts 2 and upper bolts 1 3 Install the power converter contactor onto the mounting bracket 4 Install the battery equalizer Refer to Battery Equalizer Replacement Tahoe 5 Install the power converter Refer to Power Converter Replacement Tahoe Notice Refer to Fastener Notice in Cautions and Notices 6 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 13 Ib ft Power Converter Equalizer Bracket Replacement Suburban 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 cables of the left battery 2 Remove the left trim panel Refer to Trim Panel Replacement Rear Quarter utility left in the 2001 02 C K Truck Service Manual 3 Remove the power converter Refer to Power Converter Replace
135. on block body connector 12 241 cavity D 40 ORN wire and ground 2 Does the test lamp illuminate Go to Step 13 Manual Locate and repair open in CKT 40 ORN wire between junction block body connector C4 cavity D and blackout 13 service drive switch Did you complete the repair Go to Step 15 14 Operate the system in order to 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 2001 02 LSSV Truck 8 72 Lighting Systems Body and Accessories Blackout B O Marker Lamps Always On cont d Step Action Yes No Inspect fuse s check for damaged or corroded inline connectors check for broken or partially broken wires inside 2 insulation and properly installed aftermarket equipment Did you find and correct the condition Go to Step 3 Go to Step 4 Make necessary repairs Did you complete the repair Go to Step 7 EE 1 Disconnect blackout service lamp switch 4 2 Connect a test lamp between CKT 911 PNK cavity A wire and ground Does the test lamp illuminate Got o Step 5 Go to Step 6 Repair short to power in CKT 911 PNK or CKT 900 BRN WHT wire s bet
136. operative 6 28 Converter No Voltage 6 25 Voltmeter 6 29 Voltmeter Lamp Inoperative 6 27 Repair 24V Converter Fuse Replacement 6 36 Battery Booster Slave Junction Block Replacement 6 40 Battery Tray Battery Replacement 6 39 Circuit Breaker Bracket Replacement 6 39 Circuit Breaker Replacement 12V or 24V 6 37 Jump Starting in Case of Emergency 6 34 Voltage Regulator 6 31 Schematics 6 3 Specifications Fastener 6 3 2001 02 LSSV Truck INDEX Exterior Trim Description Exterior TEIL Saee nte tls 8 98 Repair Radiator Grille Replacement 8 96 Spiecifications Fastener Tightening Specifications 8 95 F Fiberglass Top Replacement 8 157 Floor Mat Repair Floor Mat Replacement Pickup Models 8 128 Floor Mat Replacement Tahoe Suburban 8 129 Frame and Underbody Description Frame and Underbody Description 8 165 Repair Front Winch Receiver Replacement 8 163 Military Rear Receiver Hitch Replacement 8 163 Specifications Fastener T
137. or Part 12015792 Information e 2 Way M Weather Pack TWR BLK Wire Circuit No Function Pin Color A TAN WHT 901A B O Head Lamp B BRN 900A B O Marker Lamps WHT Information e 2 Way Weather Pack TWR MED GRY Wire Circuit No Function Pin Color A 900B B O Marker Lamps B DK GRN 902 B O Stop Lamps WHT 2001 02 LSSV Truck 8 26 Wirin Body and Accessories Inline Harness Connector C992 9 Inline Harness Connector C992 AS B A 10573 Connector Part e 12010973 Connector Part e 12015792 Information 2 Way F Weather Pack Information e 2 Way M Weather Pack SHD BLK TWR BLK Wire Circuit No Function Wire Circuit No Function Pin Color Pin Color A BRN WHT 900B B O Marker Lamps A BRN WHT 900A B O Marker Lamps B DK GRN 902 B O Stop Lamps B DK GRN 902A B O Stop Lamps WHT WHT Inline Harness Connector C917 Inline Harness Connector C917 Connector Part e 12010717 Connector Part 12015793 Information 3 Way F Weather iteration 3 M Weather Pack TWR BLK TWR BLK Wire Circuit No Function Wire Circuit No Function Pin Color Pin Color BRN WHT 900D B O Marker Lamps BRN 900D B O Marker Lamps B YEL 18C S T Lamp Feed B YEL 18C S T Lamp Feed BLK 150C Ground BLK 150C Ground 2001 02 LSSV Truck Body and Accessories Wirin 8 27
138. or Relay Between Converter and Equalizer Engine Electrical Component Views in Engine Electrical Engine Electrical Component Views in Engine Electrical Fuse B Inline Inline auxiliary IP 10 cm right of IP jumper harness breakout Lighting Component Views in Lighting Systems Lighting Connector End Views in Lighting Systems 2001 02 LSSV Truck Body and Accessories Wiring 8 11 Power and Grounding Components cont d Name Location Locator View Connector End View Junction Block Left of RH battery Engine Electrical Component Views in Engine Electrical Engine Electrical Connector End Views in Engine Electrical Power Converter Utility On the LR body panel Engine Electrical Component Views in Engine Electrical Engine Electrical Connector End Views in Engine Electrical Power Converter Pickup Rear body panel behind seat Engine Electrical Component Views in Engine Electrical Engine Electrical Connector End Views in Engine Electrical Trailer Harness Connector Near the center of the rear bumper Lighting Component Views in Lighting Systems Lighting Connector End Views in Lighting Systems 24 Voltmeter Lamp Mounted in the lower center Engine Electrical Component Views in Engine Electrical Engine Electrical Connector End Views in Engine Electrical 24 Voltmeter Relay
139. ormation Bulb Type W2 Axial Wire Circuit No Function Connector Part 12033873 Pin Color Information 5 Way F MIP Series 630 A BRN 9 GRY B BLK 150 Ground Wire Circuit No Function Pin Color 30 BRN WHT 901C B O Headlamp 85 TAN WHT 901B B O Switch 86 WHT 915 B O Switch 87 PNK 911E Service Lamp Switch 2001 02 LSSV Truck Engine Engine Electrical 6 23 Relay Block Module Relay Block Module cont d 1 1 2 2 EE EE 3 3 4444 24 46465 5 6 6 1 7 1 7 r8 8 9 9 Connector Part 12146836 Connector Part 12146836 Information 36 Flex Lock 280 Information 36 Flex Lock 280 Series BLK Series BLK Wire Circuit No Function Wire Circuit No Function Pin Color Pin Color A1 ORN 40B CTSY Circuit C1 WHT 352B Headlamp Circuit A2 Not Used C2 Not Used A3 RED 912B Relay Jumper C3 RED 912B Relay Jumper 4 ORN BLK 240 Park Lamp Circuit C4 BLU 545B DRL Circuit AS Not Used C5 Not Used A6 RED 912B Relay Jumper C6 RED 912B Relay Jumper A7 PNK 839A Back Up Circuit C7 GRN 1329A Horn Circuit A8 Not Used C8 Not Used A9 RED 912A Relay Power c9 RED 912B Relay Jumper B1 BLK 150A Relay Jumper D1 BLK 150C Relay Ground B2 Not Used D2 Not Used B3 ORN 40A CTSY Circuit D3 WHT 352A HDLP Circ
140. otice Refer to Fastener Notice in Cautions and Notices 4 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten the battery cable connection to 17 N m 13 Ib ft Blackout B O Switch Replacement 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 cables of the left battery 2 Unplug the connectors 1 from the switches A Hid X W lt S AE 3 Remove the nuts and washers holding the blackout switch toggles knobs 4 Remove the keyed washers from behind the IP mounting panel and pull the toggles knobs out SERVI N CE 2001 02 LSSV Truck Body and Accessories Installation Procedure 1 Install the keyed washers behind the IP mounting panel Notice Refer to Fastener Notice in Cautions and Notices 2 Insert the toggles knobs through the IP mounting panel holes and attach with the washers and nuts 1 Tighten Tighten the two nuts to 2 8 N m 2 Ib ft 3 Plug the connector 1 to the switches 4 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 N m 13 Ib ft Instrument Panel Gages and Console 8 87 2001 02 LSSV Truck 8 88 Instrument Panel Gages and Console Body and Accessories Description and Operat
141. ou complete the repair Go to Step 14 Connect a test lamp on the input side of the circuit breaker and ground Does the test lamp illuminate Go to Step 10 Go to Step 12 10 Locate the source of the overload and replace the circuit breaker Did you complete the repair Go to Step 14 11 Locate and repair the open or high resistance between the contactor and converter Did you complete the repair Go to Step 14 12 Locate and repair the open or high resistance in the power feed circuit Did you complete the repair Go to Step 14 13 Locate and repair the open or high resistance in circuit 150 Did you complete the repair Go to Step 14 14 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 Contactor Inoperative Step Action Value s Yes No Schematic Reference Engine Electrical 1 Did you review the Starting and Charging System Description and Operation Go to Step 2 Go to Description and Operation Are the batteries properly charged Go to Step 3 Go to Battery Charging in 2001 02 C K Truck Service Manual With the ignition on connect a test lamp between terminal F and ground Does the test lamp illuminate Go to Step 4 Go to Step 5 Connect a test lamp between terminal E and ground Does the test lamp illuminate Go to Step 7 Go to Ste
142. out B O Lighting Circuit of Operation 8 81 Backup LoS acna E 8 81 Instrument Panel Gages and Console 8 84 4 40 2422 1 8 84 Repair 2 2 8 85 Voltmeter 8 85 Voltmeter Blackout Switch Panel 8 85 Blackout Switch Replacement 8 86 Description and Operation 8 88 Instrument Panel and Gages Description 8 88 8 89 Schematic and Routing Diagrams 8 89 Diagnostic Information and Procedures 8 91 SYMPtOM LIS 8 91 Description and Operation 8 94 Horn with Blackout B O Control Circuit Operation ze teret rre Rte 8 94 Exterior Trim 8 95 eee een 8 95 Repair Instructions 44 8 96 Radiator Grille Replacement 8 96 Description and Operation 8 98 Exterior Trim 8 98 8 99 Specifications tate 8 99 Repair Instructions 8 100 Front Bumper Replacement
143. p 6 Locate and repair the open in circuit 39 Did you complete the repair Go to Step 18 Connect a test lamp between terminal A and ground Does the test lamp illuminate Go to Step 8 Go to Step 10 2001 02 LSSV Truck Engine Engine Electrical 6 29 Contactor Inoperative cont d Step Action Value s Yes No Locate and repair the open in circuit 150 Did you complete the repair Go to Step 18 Connect a test lamp between terminal B circuit 900 and ground Does the test lamp illuminate Go to Step 11 Go to Step 9 Replace the contactor assembly Did you complete the replacement Go to Step 18 10 Connect a test lamp between terminal C circuit 900 and ground Does the test lamp illuminate Go to Step 12 Go to Step 13 11 With the ignition on connect a test lamp to terminal D and ground Does the test lamp illuminate Go to Step 18 Go to Step 9 12 Locate and repair the open in the jumper between terminal A and C circuit 900 Did you complete the repair Go to Step 18 13 Connect a test lamp between the output stud of the 24V circuit breaker and ground Does the test lamp illuminate Go to Step 14 Go to Step 15 14 Locate and repair the open or high resistance in circuit 900 Did you complete the repair Go to Step 18 15 Connect a test lamp between the input terminal of the 24V a
144. pair may damage the vehicle or render the vehicle unsafe For Cautions and Notices refer to 2001 02 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 2001 02 General Motors LSSV Military Vehicles Service Manual Supplement This manual provides information on the diagnosis the service procedures the adjustments and the specifications for the 2001 02 GM LSSV Base Pickup Crewcab Extended Cab Tahoe Suburban and Chassis Cab Information on transmission unit repair overhaul can be found in the 2001 02 Transmission Transaxle Transfer Case Unit Repair Manual TURM available separ
145. placement Front 3 Remove the front bumper Refer to Front Bumper Replacement Pickup Models 4 Remove the bottom mounting bolts 3 washers and nuts holding the front clevis tie down support to the frame rail 5 Remove the side mounting bolts 4 washers and nuts 1 holding the front clevis tie down support to the frame rail 6 Remove the front clevis tie down support 2 Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 1 Install the front clevis tie down support 2 with the side mounting bolts 4 washers and nuts 1 Tighten Tighten the side mounting bolts to 80 95 N m 59 70 Ib ft 2 Install the bottom of the tie down support with the two bottom mounting bolts 3 Tighten Tighten the two bottom mounting nuts to 80 95 59 70 Ib ft 3 Install the front bumper Refer to Front Bumper Replacement Pickup Models Body and Accessories Bumpers 8 105 4 Install the front tie down clevis 2 Refer to Clevis Tie Down Replacement Front 5 Install the engine shield c ig E 2 Clevis Tie Down Support Replacement Front Utility Removal Procedure 1 Remove engine shield 2 Remove the front clevis tie downs Refer to Clevis Tie Down Replacement Front 3 Remove the Front Bumper Refer to Front Bumper Replacement Tahoe Suburban 4 Remove bracket 3 by remove bolts 2 Remove the side mounting bolt 1 w
146. plying to original equipment or strength could result in suspension over travel or shock breakage Suspension over travel may result in suspension component breakage 1 Raise and support the vehicle 2 Support the lower control arm with a jack stand 3 Hold the tennon end with a wrench while removing the nut 4 Remove the nut 5 Remove the upper insulator 1 Suspension Front Suspension 3 5 6 Remove the shock absorber mounting bolt 2 and nut 3 at the lower control arm 7 Remove the shock absorber 1 Installation Procedure 1 Install the shock absorber Insert the stem through the hole in the shock bracket on the frame 2 Align the shock absorber with the mounting holes in the lower control arm 3 Install the shock absorber through bolt 2 to the lower control arm and shock Notice Refer to Fastener Notice in Cautions and Notices 4 Install the shock absorber through bolt nut 3 Tighten Tighten the nut to 80 N m 59 Ib ft Install the upper insulator to the shock absorber Install the nut to the tennon end Hand tighten only Remove the safety stands Lower the vehicle Hold the tennon end with a wrench while torquing the nut Tighten Tighten the nut to 20 N m 15 Ib ft 2001 02 LSSV Truck 3 6 Front Suspension Suspension Description and Operation Front Shock Absorber Description The suspension features a heavy duty shock absorber package if equ
147. r No Voltage cont d Step Action Value s Yes No 11 Connect a test lamp between the IGN stud of the converter and ground Does the test lamp illuminate Go to Step 15 Go to Step 19 12 Locate and repair the source of the overload and replace the 12V circuit breaker Did you complete the repair Go to Step 25 13 Locate and repair the open in circuit 5 Did you complete the repair Go to Step 25 14 Locate and repair the open or high resistance in circuit 901 Did you complete the repair Go to Step 25 15 Connect a self powered test lamp to the ground terminal of the converter and ground Does the test lamp illuminate Go to Step 23 Go to Step 24 16 With the contactor energized connect a test lamp between terminal D and ground Does the test lamp illuminate Go to Step 14 Go to Step 18 17 Locate and repair the source of the overload and replace the fuse Did you complete the repair Go to Step 25 18 Connect a test lamp between terminal C and ground Does the test lamp illuminate Go to Contactor Inoperative Go to Step 20 19 Locate and repair the open of high resistance in circuit 39 Did you complete the repair Go to Step 25 20 Connect a test lamp between the 24V circuit breaker output terminal and ground Does the test lamp illuminate Go to Step 21 Go to Step 22 21 Locate and
148. repair the source of the overload or high resistance and replace the circuit breaker Did you complete the repair Go to Step 25 22 Locate and repair the open in the power circuit to the 24V circuit breaker Did you complete the repair Go to Step 25 23 Replace the power converter Did you complete the replacement Go to Step 25 24 Locate and repair the open in circuit 150 Did you complete the repair Go to Step 25 25 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 2001 02 LSSV Truck Engine Engine Electrical 6 27 Voltmeter Lamp Inoperative Step Action Value s Yes No Schematic Reference Engine Electrical 1 Did you review the Starting and Charging System Description and Operation Go to Step 2 Go to Description and Operation Connect a test lamp between cavity A of the voltmeter bulb and ground Does the test lamp illuminate Go to Step 3 Go to Step 4 Connect a self powered test lamp to cavity G 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 Replace the voltmeter bulb Did you complete the replacement Go to Step 7 Locate and repair the open or high resistance in 150 Did you complete the repair
149. retaining pin Clevis Tie Down Replacement Rear Removal Procedure 1 Remove nut 1 and bolt 2 2 Remove clevis 3 from frame 2001 02 LSSV Truck Body and Accessories Bumpers 8 115 Installation Procedure 1 Install clevis 3 to frame Notice Refer to Fastener Notice in Cautions and Notices 2 Install bolt 2 and nut 1 and tighten Notice Clevis must move once torqued Do not over torque Tighten Tighten nut and bolt to 200 148 Ib ft 2001 02 LSSV Truck 8 116 Bumpers Body and Accessories Description and Operation Bumpers The equipment described includes all bumper assemblies front and rear that are offered or modified 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 radiator brush guard several reinforcement brackets or braces clevis tie down attachments and pintle hooks The repair of some sub assemblies require removal of the rear bumpers for access while others require removal of electrical components and lamp harness connections 2001 02 LSSV Truck Body and Accessories Body Front End 8 117 Body Front End Specifications Fastener Tightening Specifications Specification Application Metric English Battery Cable Connection 17 13 Ib ft Clevis Tie Down Bolts 200 148 Ib ft Slave Connec
150. right and left taillamp connectors Body and Accessories Wiring 8 35 Installation Procedure 1 Install the rear lamp harness connector to the right and left taillamp connectors 2 Install the ground lead nut ground lead and connector to the right blackout marker lamp 3 Install the two rear lamp harness connectors 7 8 to the trailer jumper 4 nstall the rear lamp harness connector to the auxiliary rear lamp extension harness 5 Install the rear lamp harness connector to the auxiliary rear lamp extension harness 6 Install the vehicle ground lead bolt washer and harness ground Important For the Utility models Route the ground lead over the rear lamp harness connectors For the Pickup models Route the ground lead to the hole in the left frame rail 7 Install the ground lead and connector for the left blackout marker lamp 8 Install the rear lamp harness connector to the left taillamp connector Notice Refer to Fastener Notice in Cautions and Notices 9 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 13 Ib ft Trailer Wiring Harness Replacement Removal Procedure 1 Remove the rear bumper Refer to Bumper Replacement Rear or Bumper Replacement Rear Military Hitch in Bumpers Caution Refer to Battery Disconnect Caution in Cautions and Notices 2 Remove the negative cable of the
151. right battery and the 12V and 24V cables of the left battery 3 Remove the two trailer connections 2 3 from the rear lamp wiring harness jumpers 4 Remove the four bolts washers and nuts holding the harness assembly mounting bracket 4 and door 5 to the rear bumper 5 Remove the trailer wiring harness through the hole 2001 02 LSSV Truck 8 36 Wirin Body and Accessories 2001 02 LSSV Truck Installation Procedure 1 Insert the harness through the harness hole Notice Refer to Fastener Notice in Cautions and Notices 2 Install the four bolts washers and nuts holding the harness assembly mounting bracket 4 and door 5 to the rear bumper Tighten Tighten the four bolts to 5 N m 4 Ib ft Install the two trailer connectors 2 3 to the rear lamp harness connectors Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 N m 13 Ib ft Install the rear bumper Refer to Bumper Replacement Rear or Bumper Replacement Rear Military Hitch in Bumpers Winch Connector Harness Replacement Front Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices Remove the negative cable of the right battery and the 12V and 24V of the left battery Remove bolt 1 securing the electrical connector 2 to the front receiver Remove ty wraps
152. ription and Operation 8 160 Body Rear 8 160 Paint Coatings 8 161 Paint Codes eae 8 161 Frame and Underbody 8 162 Specifications eie inui 8 162 Repair Instructions 8 163 Military Rear Receiver Hitch Replacement 8 163 Front Winch Receiver Replacement 8 163 Description and Operation 8 165 Frame and Underbody Description 8 165 Body and Accessories Wiring 8 3 Wiring Systems Specifications Fastener Tightening Specifications Specifications Application Metric English Battery Cable Connections 17 N m 13 Ib ft Fender Brace Bolts 25 18 Ib ft Trailer Wiring Harness Bracket Bolts 5 4 Ib ft Schematic and Routing Diagrams 2001 02 LSSV Truck eG ge acc 5 5 yes dwn U9UIM __ Body and Accessories Q38 r r I Ang 1 I 49018 uonounr 1 i uonjoune U9UIM JUNO ejeuruueg U9uiM JUNOW HINY soneuiauos uonnqiujsig 8 4 Wirin 2001 02 LSSV Truck 8 5 irin Body and Accessories uonounr YAMS Jeye
153. s C993 Center under endgate inline to trailer Wiring Component Wiring Connector End harness Views in Wiring Systems Views in Wiring Systems C191 Interrupt harness RH engine compartment Wiring Component Wiring Connector End Views in Wiring Systems Views in Wiring Systems C192 Interrupt harness RH engine compartment Wiring Component Wiring Connector End Views in Wiring Systems Views in Wiring Systems G113 On the radiator support near the LH Lighting Component headlamp Views in Lighting Systems 2001 02 LSSV Truck 8 12 Wiring Body and Accessories Power and Grounding Components cont d Name Location Locator View Connector End View G123 The LF stud on the intake manifold Lighting Component ___ Views in Lighting Systems G200 Behind the LH of the IP below the IP fuse Lighting Component E block Views in Lighting Systems G401 At the LR frame rail behind the bumper Lighting Component M Views in Lighting Systems P103 On the rear of the IP behind the brake 2 9 booster 5102 Approx 31 5 cm left of blackout headlamp EN E breakout 105 Approx 31 5 cm right of blackout D headlamp breakout 223 Approx 21 5 cm left of blackout headlamp switch 5224 Approx 36 5 cm left of inline IP harness 2 connector breakout 229 Approx 31 0 cm left of inline IP harness E connector breakout 281 Approx 46 5 cm right of inline IP harness connector breakout
154. s Fastener Tightening Specifications Specification Application Metric English Battery Cable Connections 13 Ib ft Front Clevis Tie Down Support Bolts Pickup Models 59 70 Ib ft Front Bumper Bracket Bolts Pickup Models 63 Ib ft Front Bumper Frame Brace Bolts Pickup Models 63 Ib ft Front Bumper Bracket Bolts Tahoe Suburban 63 Ib ft Front Bumper Frame Brace Bolts Tahoe Suburban 41 Ib ft Front Clevis Bolts 148 Ib ft Front Clevis Tie Down Support Bolts Tahoe Suburban 59 70 Ib ft Radiator Grille Brush Guard Bolts 65 Ib ft Rear Bumper Brace Bolts 59 74 lb ft Rear Bumper Nuts Factory Hitch 59 74 Ib ft Rear Bumper Frame Bolts 59 74 lb ft Rear Clevis Bolts 148 Ib ft Rear Clevis Tie Down Support Bolt Factory Hitch 58 Ib ft Rear Clevis Tie Down Support Bolts 49 65 Ib ft Rear Clevis Tie Down Support Vertical Bolt 88 115 N m 65 85 Ib ft 2001 02 LSSV Truck 8 100 Bumpers Body and Accessories Repair Instructions _ Tahoe Suburban 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 radiator grille brush guard Refer to Radiator Grille Brush Guard Replacement 3 Remove the front grille Refer to Radiator Grille Replacement in Exterior Trim 4 Remove front clevis Refer to Clevis Tie Down Replacement Front 1032
155. s g s neujau s uonnquisiq punog 051 418 SEO 14Q Svs Ma yA 72 ACV LD 43 Aejay 140 aun eg suiajs s ut 5 25 uonnquisig og T S NPOW J033u02 W4 269 X 18 NH9 11 822 LHM 95 0 904 AHO 560 1 5 6 1467 092 904d 5 45 6 5 25 uonnquisig soneuieuos 53467 Buruuny eunAeg syuBiipeeH 2001 02 LSSV Truck Lighting Systems 8 47 Body and Accessories UMS seninn due 1 1 LO L NYS 90 LO L NYS 1dnuj9ju 2001 02 LSSV Truck Body and Accessories 8 48 Lighting Systems suiejss ui punoJc i 058 suiejs S ui soneuieuog 1 30019 1 uonnquisiq 1 uonounf paga 671 N1d MG 660 30019 _ _ pue Obed 1 s1uBr1 1 1 95 8 860 Wo9 1 i 2 pog MG Aejay yoojg uonounf
156. s No Locate and repair the short to voltage on circuit 545A DK 8 BLU Did you complete the repair Go to Step 9 m Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 2 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 service lamp switch in the blackout mode 2 2 Connecta test lamp at cavity C of the blackout switch and ground Does the test light illuminate Go to Step 3 Go to Step 4 Replace the blackout service lamp switch Did you complete the replacement Go to Step 9 ES Connect a test lamp to cavity A9 of the relay block and 4 ground Does the test lamp illuminate Go to Step 5 Go to Step 6 Locate and repair the short to voltage on circuit 912B RED gt 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 m 5 Locate and repair the short to voltage on circuit 839A Did you complete the repair Go to Step 9 m 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 Sche
157. s to the side rail Remove the two 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 four existing rivnuts if damaged from the box rail Installation Procedure 1 2 Apply two 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 and Accessories Body Rear End 8 153 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 two outside bolts and the two upward facing bracket bolts and nuts Tighten Tighten the two outside bolts to 26 N m 19 Ib ft Tighten the two upward facing bolts to 8 6 Ib ft 4 Install side rail adapter plates front and rear by aligning the bolt holes to the holes in the box 5 Install the troop seats Refer to Seat Replacement Troop Pickup Models in Seats 6 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 1 Remove the cargo cover from the front of the cargo cover assembly Refer to Cargo Cover Replacement 2 Remove the four bol
158. securing cables Note routing for installation Remove cable connections at the junction block Installation Procedure 1 2 3 Install cable connections at the junction block Route cable in same locations as removed and ty wrap Install connector 2 on receiver and tighten bolt 1 Notice Refer to Fastener Notice in Cautions and Notices 4 Install the negative battery cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 N m 13 Ib ft Body and Accessories Wiring 8 37 Winch Connector Harness Replacement Rear 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 of the left battery 2 Remove bolts 1 securing connector 2 to frame 3 Remove ty wraps securing harness Note routing for installation 4 Remove cable from junction block Installation Procedure 1 Install harness in original routing locations and secure with ty wraps 2 Install cable ends to the junction block and tighten 3 Install connector 2 to the frame install bolts 1 and tighten Notice Refer to Fastener Notice in Cautions and Notices 4 Install the negative battery cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 Nem 13 Ib ft Relay Mounting Bracket Replacem
159. stalled in every new GM vehicle But if a battery has filler caps be sure the right amount of fluid is there If it is low add water to take care of that first If you don t explosive gas could be present Don t get is 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 Start the vehicle with the good batteries 6 Connect the slave cable to the vehicle with the good battery 7 Allow the vehicle with the dead battery to charge for 10 minutes Note It may take up to 30 minutes to charge the battery 73772 depending on its state of charge 8 Start the 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 2001 02 LSSV Truck 6 36 Engine Electrical Engine 2001 02 LSSV Truck 24V Converter Fuse Replacement 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 cables of the left battery 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 instal
160. t Winch Receiver Replacement 8 163 Winch Mount Replacement Pickup 8 118 Winch Replacement Pickup Models 8 119 Wiring Components Power and Grounding Component Views 8 13 Power and Grounding Components 8 13 Power and Grounding Connector End VIEWS ied rs 8 25 Description reete e REGE 8 39 Repair Auxiliary Lamp Extension Harness Replacement 8 33 Auxiliary Lamp Harness Replacement lare 8 32 Lamp Harness Replacement 8 34 Relay Mounting Bracket Replacement 8 37 Trailer Wiring Harness Replacement 8 35 Winch Connector Harness Replacement FIOM xit eire odes t ei 8 36 i REND ivo tea 8 37 e eie ere ae 8 3 Specifications Fastener Tightening 8 3 2001 02 LSSV Truck 6 INDEX 2001 02 LSSV Truck
161. tery Equalizer Replacement Suburban 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 cables of the left battery 2 Remove the left trim panel Refer to Trim Panel Replacement Rear Quarter utility left in the 2001 02 C K Truck service manual 3 Remove equalizer wiring from connectors 1 Note removal position of wiring for installation 4 Remove bolts securing equalizer 2 to bracket 5 Slide equalizer from bracket remove from vehicle 2001 02 LSSV Truck 8 146 Interior Trim Body and Accessories 2001 02 LSSV Truck Installation Procedure 1 Slide the equalizer 2 into bracket and secure with bolts 2 Install wiring to equalizer connections 1 in same location as removed 3 Install the left trim panel Refer to Trim Panel Replacement Rear Quarter utility left in the 2001 02 C K Truck Service Manual Notice Referto Fastener Notice in Cautions and Notices 4 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten battery cable connections to 17 N m 13 Ib ft Power Converter Equalizer Bracket Replacement Tahoe 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 cables of the right battery 2 Remove the Power Co
162. tery and the 12V and 24V cable of the left battery 2 Remove the top cover of the trim panel to gain access to the contactor 2 3 Remove bolts securing contactor to the bracket Notice A back up wrench must be used to hold the bottom nut stationary 4 Remove the wiring on the contactor 2 Note position of wiring for installation Installation Procedure Notice Refer to Fastener Notice in Cautions and Notices 1 Install the wiring to the contactor 2 The same position as removed Notice A back up wrench must be used to hold the bottom nut stationary Tighten Tighten the larger contact terminal nuts to 5 6 N m 45 55 Ib in Tighten Tighten the smaller coil terminal nuts to 1 2 N m 12 18 Ib in 2 Install the contactor 2 to the mounting bracket 3 Install the top cover to the trim panel 4 Install the negative cable of the right battery and the 12V and 24V cables of the left battery Tighten Tighten the battery cable connections to 17 13 Ib ft Contactor Replacement Suburban Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Remove the negative cable of the right battery and 12V and 24V cables of the left battery 2 Remove the left trim panel Refer to Trim Panel Replacement Rear Quarter Utility Left in the 2001 02 C K Truck Service Manual Body and Accessories Interior Trim 8 139 Notice A back up wrench must be used to hold the bottom nut stat
163. tices 6 Finish installing all attaching hardware Install the nuts and bolts Tighten Tighten the frame bolts to 80 100 Nem 59 74 Ib ft Tighten the brace bolts to 80 100 N m 59 74 Ib ft 7 Connect the 12V and 24V cables of the left battery and the negative cable of the right battery 8 Install the lower step pad 9 Install the pintle hook into the receiver Tighten Tighten the battery cable connections to 17 N m 13 Ib ft Bumpers 8 111 2001 02 LSSV Truck 8 112 5 Body and Accessories 2001 02 LSSV Truck Clevis Tie Down Support Replacement Rear Factory Hitch Pickup Models Removal Procedure 1 Remove the rear bumper Refer to Bumper Replacement Rear or Bumper Replacement Rear Factory Hitch 2 Remove clevis Refer to Clevis Tie Down Replacement Rear 3 Remove the bolts 1 washers and nuts holding the tie down bracket to the 2 receiver mount 4 Remove the tie down bracket 2 Installation Procedure 1 Install the tie down bracket 2 aligning the bolt holes Notice Refer to Fastener Notice in Cautions and Notices 2 Install brace 3 and bolts 1 Tighten Tighten the bolts to 78 N m 58 Ib ft 3 Install the rear bumper Refer to Bumper Replacement Rear or Bumper Replacement Rear Factory Hitch Clevis Tie Down Bracket Replacement Rear Utility Extended Cab Removal Procedure 1 Remove the rear clevis Refer to Clevis Tie
164. tion Each of the vehicles features a five speed automatic or four speed automatic transmission with overdrive and a two speed transfer case A vent tube is mounted between the transmission transfer case which attaches to a hose filter and vent cap The filter must be inspected occasionally to see if it needs to be replaced Refer to Periodic Maintenance Inspections in Maintenance Schedule section in 2001 02 LSSV Operator s Manual Supplement Transfer Case 4 15 2001 02 LSSV Truck Engine Table of Contents 6 1 Section 6 Engine Engine Electrical 6 3 Jump Starting in Case of Emergency 6 34 Specifications tete 6 3 24V Converter Fuse Replacement 6 36 Schematic and Routing Diagrams 6 3 Circuit Breaker Replacement 12V or 24V 6 37 Component Locator eene 6 9 Circuit Breaker Bracket Replacement 6 39 Starting and Charging Component Views 6 9 Battery Tray Battery Replacement 6 39 Connector End Views eene 6 22 Battery Booster Slave Junction Block Starting and Charging Connector End Views 6 22 Replacement A 6 40 Diagnostic Information and Procedures 6 25 Description and Operation 6 42 Symptom eoa Redi tuf 6 25 Battery Description 12V and 24V
165. tion 3 24 Volt Connection 6 Power Converter 2001 02 LSSV Truck Engine Engine Electrical 6 15 Battery Equalizer E X Legend 1 24 Volt Connection 4 Battery Equalizer 2 12 Volt Connection 5 LED Status Indicator 3 Ground Connection 2001 02 LSSV Truck 6 16 Engine Electrical Engine Converter Protection Contactor Starter Relay 5 s gt SSS 1 Boot 6 From the Ignition Stud Power Converter 2 From 24V Equalizer Stud 7 Ground from Power Converter 3 Contactor Starter Relay 8 From 24V Circuit Breaker 4 From 24V Converter Stud 9 From Circuit Breaker 24V Contactor Stud 5 Engine Wiring Harness 2001 02 LSSV Truck Engine Engine Electrical 6 17 Bulkhead Junction Block Legend 1 Junction Block 6 Negative Winch Cable Front 2 Jumper Plate 7 Negative Battery Cable 3 Ground Connection 8 Positive Battery Cable 4 Mounting Bracket 9 Positive Winch Cable Front 5 Negative Winch Cable Rear 10 Positive Winch Cable Rear 2001 02 LSSV Truck 6 18 Engine Electrical Engine 24V Battery Booster and Starter Cable Junction Block Legend 1 Positive Battery Cable 4 Junction Block Post Nut 2 Junction Block 5 Positive Winch Cable Permanent Mount 3 Alternator Output Cable 6 Junction Block Post 2001 02 LSSV Truck Engine Engine Electrical 6 19 Junction Block IP Legend 1 Cavity A
166. tion Interior 8 149 Repair 24 Voltmeter Relay Replacement Pickup 8 133 24 Voltmeter Relay Replacement Suburban see 8 135 24 Voltmeter Relay Replacement Tahoe 8 134 Battery Equalizer Replacement Suburban 8 145 Battery Equalizer Replacement Tahoe 8 144 Battery Equalizer Bracket Replacement Pickup 8 143 Contactor Replacement Pickup Models 8 136 Contactor Replacement 8 138 Contactor Replacement 8 138 Floor Mat Replacement Pickup Models 8 128 Floor Mat Replacement Tahoe Suburban 8 129 Government Vehicle Data Plate 8 130 Power Converter Replacement Suburban 8 142 Power Converter Replacement Tahoe 8 141 Power Converter Bracket Replacement Pickup 8 140 Power Converter Equalizer Bracket Replacement 8 147 Power Converter Equalizer Bracket Replacement Tahoe 8 146 Rear Compartment Side Trim Panel Replacement Tahoe Suburban 8 126 Weapons Mount Replacement Floor Mount rt eere 8 132 Weapons Mount
167. tion Yes No Schematic Reference Horns Schematic 1 Did you review Horns Description and Operation Go to Description Go to Step 2 and Operation Inspect inline fuse A and B check for damaged or corroded inline connectors check for broken or partially broken wires 2 inside insulation and properly installed aftermarket equipment Did you find and correct the condition Go to Step 3 Go to Step 4 Locate and repair as needed and repair circuit Did you complete the repair Go to Step 25 s j Depress and hold the horn switch Does the LH horn operate Go to Step 5 Go to Step 10 Backprobe the RH horn connector with a test lamp from 5 cavity Ato B Does the test lamp illuminate Go to Step 7 Go to Step 6 Locate and repair open in BLK 250 wire between the RH 6 horn and G112 Did you complete the repair Go to Step 25 Backprobe the RH horn connector with a test lamp from 7 cavity B to ground Depress and hold the horn switch Does the test lamp illuminate Go to Step 8 Go to Step 9 Replace the RH horn Did you complete the replacement Go to Step 25 Locate and repair open in DK GRN 29 wire between the RH 9 horn and 124 Did you complete the repair Go to Step 25 Disconnect the LH horn connector Connect a test lamp 10 from the LH horn connector cavity B to ground press horn Does the test lamp illuminate Go to Step 11 Go to Step 14 Connect a test lamp from the LH horn connector cavity
168. to Step 2 and Operation 1 Place the blackout service lamp switch in the blackout mode 2 2 Connecta test lamp at cavity C of the blackout switch and ground Does the test light illuminate Go to Step 3 Go to Step 4 Replace the blackout service lamp switch i Did you complete the replacement Go to Step 9 4 Connect test lamp to cavity 85 circuit 9128 of the turn 4 signal relay and ground Does the test lamp illuminate Go to Step 5 Go to Step 6 Locate and repair the short to voltage on circuit 912B RED i 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 d Did you complete the replacement Go to Step 9 Locate and repair the short to voltage on circuit 1398 8 PNK BLK Did you complete the repair Go to Step 9 m Operate the system in order to verify the repair 1 Did you correct the condition System OK Go to Step 2 2001 02 LSSV Truck 8 76 Lighting Systems Body and Accessories 2001 02 LSSV Truck Repair Instructions Headlamp Replacement Blackout B O Removal Procedure 1 Remove the radiator grille brush guard Refer to Radiator Grille Brush Guard Replacement in Bumpers 2 Remove upper grille baffle 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 o
169. to diagnose the symptom Blackout B O Headlamp Inoperative Blackout B O Headlamp Always On Headlamps Operate in Blackout B O Mode Backup Lamps Inoperative Stoplamps Inoperative Blackout Marker Lamps Blackout B O Marker Lamps Always On DRL Operate in Blackout B O Mode e Backup Lamps Operate in Blackout Mode e Park Lamps Operate in Blackout Mode CTSY Lamps Operate in Blackout B O Mode Turn Signals Operate in Blackout B O Mode Blackout Headlamp 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 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 service lamp switch in blackout mode 2 Turn blackout headlamp switch to ON position 3 3 Connecta test lamp to CKT 901 TAN WHT at connector C192 cavity A of the blackout headlamp and ground Does the test lamp illuminate Go to Step 4 Go to Step 7 1 Disconnect the blackout lamp 2 Connecta self powered test lamp at CKT 151C BLK and ground Does the test lamp illuminate Go to Step 6 Go to Step 5 Locate and repair open CKT 151 BLK between blackout 5 headlamp and 6113
170. to supply the 12V system The 24V system is provided from the positive post of the LH battery This generators regulator uses digital techniques to supply the rotor current and thereby controlling the output voltage The rotor current is proportional to the width of the electrical pulses supplied to it by the regulator When the ignition Switch is placed in run narrow width pulses are supplied to the rotor creating a weak magnetic field When the engine is started the regulator senses generator rotation by detecting AC voltage at the stator through an internal wire Once the engine is running the regulator varies the field current by controlling the pulse width This regulates the generator output voltage for proper battery charging and electrical System operation Engine Engine Electrical 6 43 The digital regulator controls the bat indicator lamp with a solid state lamp driver The lamp driver turns on the lamp whenever undervoltage overvoltage or a stopped generator is detected Voltage is available to the indicator lamp and the generator when the ignition switch is in bulb test or start The 20 amp gauges fuse 4 located in the fuse block provides voltage through the CKT 39 PNK wire to instrument cluster pin 22 When there is no current flowing battery voltage is available at pin 19 and provides the generator through the CKT 25 BRN wire Generator connector cavity B connects to generator pin L This voltage i
171. tor Bolts 3 2 Ib ft Slave Connector Terminal Bolts 6 4 Ib ft Winch Mount Bolts 68 50 Ib ft Winch to Mount Bolts 47 54 35 40 Ib ft 2001 02 LSSV Truck 8 118 Body Front Body and Accessories 2001 02 LSSV Truck Repair Instructions Slave Connector Replacement Removal Procedure Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the negative cable of the right battery and the 12V and 24V cables of the left battery 2 Remove negative cable from connection 2 3 Remove positive cable from connection 3 4 Remove the four bolts 1 and nuts holding the booster slave connector assembly and gasket to the bracket Installation Procedure Notice The gasket must mount to the square back of the booster slave connector assembly Notice Refer to Fastener Notice in Cautions and Notices 1 Install the booster slave connector with gasket and tighten bolts 1 Tighten Tighten the four bolts to 3 N m 2 Ib ft 2 Install the positive battery cable to the connection 3 3 Install the negative battery cable to the connection 2 Tighten Tighten both connections to 6 N m 4 Ib ft 4 Install the negative cable of the right battery and the 12V and 24V 6 cables of the left battery Tighten Tighten battery cables to 17 13 Ib ft Winch Mount Replacement Pickup Models Removal Procedure Caution Refer to Battery Disconne
172. ts from the front end rails as needed 3 Remove the four rivnuts by drilling out if damaged 2001 02 LSSV Truck 8 154 Body and Accessories 2001 02 LSSV Truck Installation Procedure 1 Apply two 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 TX0016183 instead 2 Install the four rivnuts if damaged to the mounting holes using a rivnut installer Notice Refer to Fastener Notice in Cautions and Notices 3 Install the two front end rails to the front end of the box with four bolts over the four rivnuts Tighten Tighten the four bolts to 8 6 Ib ft 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 four bolts from the end gate rail as needed 3 Remove the four rivnuts by drilling out if damaged Installation Procedure 1 Apply two 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 TX0016183 instead 2 Install the four rivnuts if damaged to the mounting holes using a rivnut installer Notice Refer to Fastener Notice in C
173. uit B4 BLK 150A Relay Jumper D4 BLK 150A Relay Jumper B5 Not Used D5 Not Used B6 ORN BLK 240B Park Lamp Circuit D6 BLU 545A DRL Circuit B7 BLK 150A Relay Jumper D7 BLK 150A Relay Jumper B8 Not Used D8 Not Used B9 PNK 839B Back Up Circuit D9 GRN 1329B Horn Circuit 2001 02 LSSV Truck 6 24 Engine Electrical Multi Mount Winch Vehicle Connector Engine Multi Mount Winch Vehicle Connector Front Rear B A B A 10804 10804 Connector Part e TX017639 Connector Part e TX017640 Information e 2 Way Red Information e 2 Way Red Wire Circuit No Function Wire Circuit No Function Pin Color Pin Color A BLK RED 1 Positive A BLK RED 1 Positive B BLK 150 Negative B BLK 150 Negative Multi Mount Winch Connector B 10805 Connector Part TX017639 or TX017640 Information 2 Way RED Wire Circuit No Function Pin Color A BLK 150 Negative B BLK RED 1 Positive 2001 02 LSSV Truck Engine Engine Electrical 6 25 Diagnostic Information and Procedures Symptom List Note For vehicle no start condition refer to Diagnostic System Check in the 2001 02 C K Truck Service Manual Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom Converter No Voltage Voltmeter Lamp Inoperative Battery Equalizer Inoperative Contactor Inoperative Voltmeter Inoperative
174. ure 1 Remove bolts securing weapons mount 1 and remove mount 2 Remove floor mat Refer to Carpet Replacement Front and Carpet Replacement Rear in 2001 02 C K Truck Service Manual Installation Procedure 1 Using the old floor mat as a template cut weapons mount holes in the new floor mat 2 Install the floor mat Refer to Carpet Replacement Front and Carpet Replacement Rear in 2001 02 C K Truck Service Manual Body and Accessories Interior Trim 8 129 Notice Refer to Fastener Notice in Cautions and Notices 3 Install weapons mount 1 and install bolts Tighten Tighten bolts to 8 6 Ib ft Floor Mat Replacement Tahoe Suburban Removal Procedure 1 Remove bolts securing weapons mount 1 and remove mount 2 Remove floor mat Refer to Carpet Replacement Front Utility in 2001 02 C K Truck Service Manual 2001 02 LSSV Truck 8 130 Interior Trim Body and Accessories 2001 02 LSSV Truck Installation Procedure 1 Using the old floor mat as a template cut weapons mount holes in the new floor mat 2 Install the floor mat Refer to Carpet Replacement Front Utility in 2001 02 C K Truck Service Manual Notice Refer to Fastener Notice in Cautions and Notices 3 Install weapons mount 1 Install fasteners and tighten Tighten Tighten bolts to 8 N m 6 Ib ft Government Vehicle Data Plate Replacement Removal Procedure 1 Drill out the four rivets 2 R
175. ve bolt 1 securing electrical connector 2 to the front receiver 2001 02 LSSV Truck 8 164 Frame and Underbod Body and Accessories 3 Remove bolt 5 and remove clevis tie down 4 from frame 4 Remove bolts 1 3 securing receiver to the frame 5 Remove receiver 2 from frame Installation Procedure 1 Install receiver 2 to the frame and align holes 2 Install bolts 1 3 securing receiver to frame 3 Install clevis tie down 4 and bolt 5 4 Tighten all bolts 5 Install connector 2 on receiver and tighten bolt 1 6 Install the front bumper Refer to Front Bumper Replacement Tahoe Suburban 2001 02 LSSV Truck Body and Accessories Frame and Underbody 8 165 Description and Operation Frame and Underbody Description The underbody equipment includes the hitch receiver rear and hitch receiver front Hitch Receiver Hitch receiver is frame mounted The receiver will allow use of different components such as pintle hook or a multi mount winch The hitch receiver is also mounted on the front of the Utility vehicles The military hitch receiver is accessible through the rear bumper to accommodate a higher trailer torque height The factory hitch receiver is accessible through the bottom of the bumper and will accommodate a standard trailer torque height 2001 02 LSSV Truck INDEX A Auxiliary Lamp Extension Harness Replacement Rear
176. ween blackout service lamp switch 5 and blackout marker lamps ES Did you complete the repair Got o Step 7 Replace blackout service lamp switch Did you complete the replacement Got o Step 7 Operate the system in order to verify the repair i 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 Description Operation Go to Step 2 and Operation 1 Place the blackout service lamp switch in the blackout mode 2 2 Connecta test lamp at cavity C of the blackout switch and ground Does the test light illuminate Go to Step 3 Go to Step 4 Replace the blackout service lamp switch i Did you complete the replacement Go to Step 9 4 Connect a test lamp to cavity C6 of the relay block 4 ground Does the test lamp illuminate Go to Step 5 Go to Step 6 Locate and repair the short to voltage on circuit 912 RED Did you complete the repair Go to Step 9 m Remove DRL interrupt relay from the relay module Are the DRL s illuminated Go to Step 8 Go to Step 7 Replace the DRL relay d Did you complete the replacement Go to Step 9 4 2001 02 LSSV Truck Body and Accessories Lighting Systems 8 73 DRL Operate in Blackout B O Mode cont d Step Action Ye

2001/02 general motors lssv military vehicles service manual

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