2000 Chevrolet Suburban C1500 Complete Service Manual

The document provides detailed instructions and specifications for servicing and repairing various components of the 2000 Chevrolet Suburban C1500, including drive axles, air bag systems, HVAC systems, steering components, and electronic modules. It includes torque specifications, safety precautions, special tools, and step-by-step procedures for component removal, installation, and programming.

Steering Knuckle and Drive Axles

•    Removal of steering knuckle involves cotter pins, tie rod end, and ball joints.

•    Use specific tools like Ball Joint Separator (J-23742) for “T” Series models.

•    Install new seals using Seal Installer tools for different series.

•    Torque specifications include axle shaft nut at 147 ft-lbs and ball joint nuts at 72 ft-lbs.
Air Bag System (SIR)

•    Air bag system precautions include disabling SDM and wearing safety gear.

•    Steps for disabling system: remove fuse, disconnect CPA clips, and module connectors.

•    Activating system involves reconnecting modules and installing CPA clips.

•    Passenger-side air bag module removal requires disconnecting yellow connectors and mounting nuts.
HVAC System

•    Replace air inlet actuators by accessing glove box and trim panels.

•    Install clutch coil using J-tools like J-33024 and J-8433-1.

•    Ensure seals are clean and lubricated before installation.
Automatic Transmissions

•    Valve body servicing includes tightening bolts in specified sequence.

•    Use Transmission Assembly Lubricant (J-36850) for reassembly.
Programming and Theft Deterrent

•    Off-board programming requires Tech 2 and proper VIN input.

•    Theft deterrent system learn procedure requires clearing all codes and using Tech 2.

•    Steering Knuckle Removal: Includes steps for removing cotter pins, tie rod ends, and separating ball joints. Specific tools and torque specifications are provided.

•    Air Bag System: Covers disabling, activating, and safety precautions for airbag handling, including SDM and airbag module procedures.

•    Torque Specifications: Includes detailed torque values for various components like axle shaft nuts, ball joints, and tie rod ends.

•    HVAC System Maintenance: Describes procedures for actuator replacement, compressor clutch assembly, and related tools.

•    Programming Control Modules: Details off-board programming steps and the use of Tech 2 for ECU calibration and theft deterrent system relearn.

•    Power Steering Pump: Explains disassembly and reassembly of pump components, including seals, vanes, and retaining rings.

•    SIR Coil Adjustment: Provides steps for centering and installing SIR coil assemblies, with notes on pre-centered coils.

•    Automatic Transmissions: Outlines servicing procedures for valve body and pressure switch installation, including bolt tightening sequences.

Main Points from All Chapters
Steering Knuckle and Drive Axles

•    Removal and installation involve cotter pins, tie rod ends, and ball joints.

•    Use specific tools like Ball Joint Separator (J-23742) for separation.

•    Torque specifications include axle shaft nut (147 ft-lbs) and ball joint nuts (72 ft-lbs).
Air Bag System (SIR)

•    Precautions include disabling the Supplemental Inflatable Restraint (SIR) system before repairs.

•    Disabling and activating the system involve removing fuses and reconnecting components.

•    Diagnostic procedures include checking for Diagnostic Trouble Codes (DTCs) and repairing airbag-related issues.
HVAC System

•    Procedures for replacing air inlet actuators and clutch coil installation.

•    Use of specific tools and lubrication of seals during reassembly.

•    Evacuation and recharging of refrigerant systems after repairs.
Automatic Transmissions

•    Valve body servicing includes proper bolt tightening sequences.

•    Use of Transmission Assembly Lubricant (J-36850) for reassembly.

•    Programming and calibration procedures for control modules.
Programming and Theft Deterrent Systems

•    Powertrain Control Module (PCM) and Body Control Module (BCM) programming requires specialized tools like Tech 2 and Techline terminal.

•    Theft deterrent system relearn procedures include 10-minute and 30-minute relearn cycles.

•    Modules will learn new passwords or configurations after programming.
Braking System

•    Inspection and refinishing of brake rotors based on wear conditions like cracks, rust, and thickness variation.

•    Steps for hydraulic brake system diagnosis and flushing contaminated brake fluid.

•    Replacement of components with internal rubber seals if fluid contamination is detected.
Suspension System

•    Real-Time Damping (RTD) system controls vehicle ride by adjusting damper solenoid valves.

•    Diagnostic procedures for malfunctions displayed in the Instrument Panel Cluster (IPC).

•    Automatic Level Control (ALC) for maintaining proper vehicle height under varying loads.
Electrical and Diagnostic Systems

•    Use of scan tools for retrieving and clearing DTCs from various modules.

•    Inspection of wiring, fuses, and connections for electrical faults.

•    Communication checks between modules on the Class 2 serial data circuit.
General Procedures

•    SIR Diagnostic System Check ensures proper airbag operation and diagnoses malfunctions.

•    Steps for replacing or programming components like sensors, modules, and actuators.

•    Proper use of tools and adherence to torque specifications during installation.
A/C System

•    Procedures for removing and installing A/C refrigerant filters and recharging systems.

•    Leak detection and testing fittings after repairs.

•    Steps for accumulator removal and refrigerant recovery.
These points summarize the key procedures, tools, and diagnostic methods across all chapters.

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