SB-10043844-5593
File in Section:

Service Bulletin

06 - Engine

Bulletin No.:

09-06-03-007A

Date:

February, 2012

TECHNICAL
Subject:

Malfunction Indicator Lamp (MIL) Illuminated, DTC P0480 and/or P0481 Set –
Temperature Gauge Indicates Hot – Cooling Fans Intermittent or Inoperative
(Install Revised Cooling Fan Relay and Harness Assembly)

Models:

2006-2009 Chevrolet Impala Police Sedan (RPO 9C1 Only)
2010 Chevrolet Impala Police Sedan Equipped With RPO 9C1 and Without RPO WRH
2011 Chevrolet Impala Police Sedan Equipped With RPO 9C1 and/or 9C3 and Without
RPO WRH

This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin
Number 09-06-03-007 (Section 06 – Engine/Propulsion System).

Condition

Cause

Some customers may comment that the instrument
panel temperature gage indicates hot.
Some customers may also comment that the
malfunction indicator lamp (MIL) is illuminated.
The technician may observe that DTC P0480 and/or
P0481 are set as current or in history and/or the engine
cooling fans are intermittent in operation or inoperative.

This condition may be caused by high underhood
bussed electrical center (UBEC) temperatures which
may result in the cooling fans becoming intermittent or
inoperative under certain operating conditions.

Copyright 2012 General Motors LLC. All Rights Reserved.

Page 2

February, 2012

Bulletin No.: 09-06-03-007A

Correction
A revised engine cooling fan relay and harness
assembly has been released, to reposition the cooling
fan relays for increased air circulation.
1. Turn OFF the ignition, all electrical components,
lamps, accessories and the scan tool.
Open the hood.

1588878

2. Remove the RH front fender upper diagonal brace
bolts (1). Release the retainer that secures the
wiring harness from the bottom of the brace (2),
then remove the upper diagonal brace.

3. Loosen the negative battery cable terminal nut and
remove the battery cable terminal from the battery.
Refer to Battery Negative Cable Disconnection and
Connection in SI.
4. Open the positive battery cable terminal cover,
loosen the battery cable terminal nut and remove
the battery cable terminal from the battery.

Bulletin No.: 09-06-03-007A

February, 2012

1617170

5. Remove the battery insulator.

Page 3

1592786

12. Remove the fuse block underhood electrical center
cover (1).

1552775

6. Remove the battery hold down bolt and the
hold down.
Note: Do not tip the battery more than 40 degrees
during removal.
7. Remove the battery.
8. Release the inner RH headlamp retainer by pulling
the retainer upward.
9. Remove the RH headlamp assembly bolt.
10. Pull the headlamp from the outboard edge in order
to release the lock pin from the fender flange
retainer.
11. Disconnect the electrical connector before
removing the headlamp from the vehicle.

2292127

Note: Observe the positions and orientations of the
forward lamp battery supply harness terminal and the
fusible links on the studs before removing.
13. At the top of the fuse block disconnect the two
fasteners on the fuse block battery studs and
remove the forward lamp battery supply harness
terminal and the fusible links. Remove the
fasteners (1) securing the electrical center
board (2).
14. Unlock the tabs on the electrical center board, then
evenly lift up on the board in order to remove it.

Page 4

February, 2012

Bulletin No.: 09-06-03-007A

1962892

15. In the illustration above observe the orientation of
the schematic for the fuse block. Identify the
location of connectors X1 and X3.

1581655

16. Locate and mark for reference, the following circuit
terminals:
• Connector X1, Circuit 473, 0.35 D-BU, Pin C7,
High Speed Cooling Fan Relay Control
• Connector X1, Circuit 335, 0.35 D-GN, Pin H7,
Low Speed Cooling Fan Relay Control

Bulletin No.: 09-06-03-007A

February, 2012

Page 5

1581659

17. Locate and mark for reference, the following circuit
terminals:
• Connector X3, Circuit 409, 3 L-BU, Pin D1,
Cooling Fan - Right Supply Voltage
• Connector X3, Circuit 532, 3 GY, Pin E1,
Cooling Fan - Left Low Reference
• Connector X3, Circuit 504, 3 WH, Pin F2,
Cooling Fan - Left Supply Voltage

2293586

2293684

2292182

18. Remove both fuse block engine harness
connectors X1 (1) and X3 (2) from their respective
cavities.
18.1. Release and remove the bottom cover on
both connectors.

18.2. Examine the X3 connector pins (1) and
connector wiring (1) for evidence of
overheating as shown.
⇒ If evidence of overheating is observed,
continue with this repair.
⇒ If evidence of overheating is not observed refer
to the appropriate DTCs in Engine Cooling or
Symptoms - Engine Cooling in SI.

Page 6

February, 2012

Bulletin No.: 09-06-03-007A

20. Secure the bracket and relay assembly to the
radiator core support using the rivets that were
supplied.
21. Remove the screw from the top of the windshield
washer solvent container filler neck at the RF
fender flange in order to provide additional
clearance for routing the revised harness.

2291981

19. Position a ruler on the top of the upper radiator
support (2) as shown. Align the ruler with the
arrows (1) and mark the 165 mm (6.5 in) area with
a paint stick or suitable marker.
2291754

22. Route the revised harness (1) out from the engine
compartment through the opening.
Note: Route the maxi fuse leads one at a time through
the fender flange opening.
Route the harness back into the engine
compartment between the windshield washer
solvent container filler neck (2) and the RF fender
flange.

2293847

19.1. Position the inboard edge of the cooling fan
relay bracket (3) that was supplied with the
revised harness assembly, 22 mm (0.86 in)
from the outboard edge of the RH engine
mount strut and tightly against the back
edge of the radiator support.
Note: Align/adjust the ends of the bracket (3) over the
radiator (2) slightly if necessary so that the holes in the
bracket DO NOT sit over any spot welds (1).
19.2. Mark the location of the holes in the bracket
on the upper radiator support. Drill the holes
using a 5 mm (3/16 in) drill bit.

2292059

23. Verify the proper routing of the harness as shown.

Bulletin No.: 09-06-03-007A

February, 2012

2292182

24. Using a suitable tool, open the engine harness
conduit (3) for the X1 connector approximately
100 mm (4 in) from the entry point at the fuse block
and extract the:
• High Speed Cooling Fan Relay Control Circuit
• Low Speed Cooling Fan Relay Control Circuit

Page 7

26. When performing the following steps, adjust the
location of the cuts at least 40 mm (1.5 in) apart in
order to allow the splices to lay end to end.
26.1. Cut both of the fan supply voltage circuits
approximately 100 mm (4 in) from the entry
point at the fuse block or at a point where
the insulation and flexibility of the wire
appear normal.
26.2. Cut the fan low reference circuit
approximately 100 mm (4 in) from the entry
point at the fuse block or at a point where
the insulation and flexibility of the wire
appear normal.
26.3. Cut both of the fan relay control circuits
approximately 100 mm (4 in) from the entry
point at the fuse block.
27. Strip approximately 7.5 mm (0.313 in) of insulation
from each of the five wires to be spliced.
27.1. Do not nick or cut any of the strands. Inspect
the stripped wire for nicks or cut strands.
27.2. If the wire is damaged, repeat this procedure
after removing the damaged section.

68642

Note: Adding heat shrink tubing to the wire before
splicing is advised in order to protect the integrity of the
DuraSeal splices.
2292182

25. Using a suitable tool, open the engine harness
conduit (4) for the X3 connector approximately
100 mm (4 in) from the entry point at the fuse block
and extract the:
• Cooling Fan - Right Supply Voltage Circuit
• Cooling Fan - Left Low Reference Circuit
• Cooling Fan - Left Supply Voltage Circuit
Important: Examine the cooling fan supply voltage
and low reference circuit wires for discoloration, loss of
insulation and brittleness in order to determine a good
point to cut and splice.

28. Compress handles until the ratchet mechanism
automatically opens the J-38125-8 Splice Crimp
Tool. Place a green DuraSeal splice sleeve in
nest (1) as indicated above. Position the sleeve so
that the crimp falls midway between the end of the
barrel and the stop. Close the tool handles slightly
in order to firmly hold the splice sleeve in the
proper nest (1).

Page 8

February, 2012

68639

29. Insert the D-BU High Speed Cooling Fan Relay
Control circuit wire (1) into the barrel (2) of the
splice sleeve until the wire hits the barrel stop (3).

Bulletin No.: 09-06-03-007A

9503

32. Use a heat torch to apply heat to the center area of
the sleeve while rotating and gradually moving to
the open ends of the tubing. The tubing will shrink
completely as the heat is moved along the
insulation. A small amount of sealant will come out
of the end of the tubing when sufficient shrinkage
has occurred.
33. Repeat steps 28 through 32 for the D-GN Low
Speed Cooling Fan Relay Control Circuit wire.

9502

30. Compress handles until the ratchet mechanism
automatically releases in order to obtain a secure
crimp.
31. Repeat steps 29 and 30 for the opposite end of
the splice.

68642

Note: Adding heat shrink tubing to the wire before
splicing is advised in order to protect the integrity of the
Dura Seal splices.
34. Compress handles until the ratchet mechanism
automatically opens the J-38125-8 Splice Crimp
Tool. Place a yellow DuraSeal splice sleeve in
nest (3) as indicated above. Position the sleeve so
that the crimp falls midway between the end of the

Bulletin No.: 09-06-03-007A

February, 2012

Page 9

barrel and the stop. Close the tool handles slightly
in order to firmly hold the splice sleeve in the
proper nest (3).

9503

68639

35. Insert the Cooling Fan - Left Low Reference circuit
wire (1) into the barrel (2) of the splice sleeve until
the wire hits the barrel stop (3).

9502

36. Compress handles until the ratchet mechanism
automatically releases in order to obtain a secure
crimp.
37. Repeat steps 35 and 36 for the opposite end of
the splice.

38. Use a heat torch to apply heat to the center area of
the sleeve while rotating and gradually moving to
the open ends of the tubing. The tubing will shrink
completely as the heat is moved along the
insulation. A small amount of sealant will come out
of the end of the tubing when sufficient shrinkage
has occurred.
39. Repeat steps 34 through 38 for the:
• Cooling Fan - Right Supply Voltage Circuit
• Cooling Fan - Left Supply Voltage Circuit
40. Reinsert the High and Low Speed Cooling Fan
Relay Control Circuit wires coming from the ECM
back into the respective conduit for the harness
and tape as needed.
41. Route the new spliced High Speed and Low Speed
Cooling Fan Relay Control Circuit wires under the
fuse block and toward the RH fender flange.

Page 10

February, 2012

Bulletin No.: 09-06-03-007A

2292783

42. Insert any excess wire length for the Cooling Fan
Low Reference Circuit, Right Supply Voltage
Circuit and Left Supply Voltage Circuit back into
the conduit (1) from which it was extracted in the
area by the RH fender flange and tape as needed.

2292127

45. Install the electrical center board (2). Ensure that
the tabs have locked in place.
Install the fasteners (1).

Tighten
Tighten the fasteners to 7 Y (62 lb in).

2292816

43. Install the ground wire grommet from the revised
harness assembly at the existing G 100 ground
location (1) as shown.

Tighten
Tighten the fastener to 7 Y (62 lb in).
44. Install and seat the X1 and X3 electrical
connectors into the fuse block. Verify the proper
positioning of all four connectors in the fuse block.

2292952

46. Install the forward lamp battery supply harness
terminal and the fusible links (1) to the LH and RH
fuse block battery studs in their original positions
and orientations.

Bulletin No.: 09-06-03-007A

February, 2012

Page 11

Note: Do not tip the battery more than 40 degrees
during installation.
50. Install the battery.
51. Install the battery hold down and bolt.

Tighten
Tighten the bolt to 18 Y (13 lb ft).
52. Install the battery insulator.
Note: Clean any existing oxidation from the contact
face of the battery terminal and battery cable using a
wire brush before installing the battery cable to the
battery terminal.
53. Install the positive battery cable terminal to the
battery.
54. Tighten the positive battery cable terminal nut.

Tighten

2292987

47. Route the shortest Maxi-Fuse ring terminal lead (2)
to the RH fuse block stud (2). Maintain sufficient
clearance.
Route the longest Maxi-Fuse ring terminal lead (1)
over the top of the fuse block to the LH fuse block
stud (1). Maintain sufficient clearance.

Tighten
Tighten the fasteners to 7 Y (62 lb in).

Tighten the nut to 15 Y (11 lb ft).
55. Snap closed the positive battery cable terminal
cover.
Note: Clean any existing oxidation from the contact
face of the battery terminal and battery cable using a
wire brush before installing the battery cable to the
battery terminal.
56. Install the negative battery cable terminal to the
battery. Refer to Battery Negative Cable
Disconnection and Connection in SI.
57. Tighten the negative battery cable.

Tighten
Tighten the nut to 15 Y (11 lb ft).
58. Install the screw at the top of the windshield
washer solvent container filler neck at the RF
fender flange.

Tighten
Tighten the screw to 1 Y (9 lb in).

1592786

48. Install the fuse block underhood electrical center
cover (1).
49. Enclose as much as possible of the revised
harness assembly in protective conduit and
tape as needed.

Page 12

February, 2012

Bulletin No.: 09-06-03-007A

1588878

59. Install the retainer that secures the wiring harness
to the bottom of the brace (2), then install the upper
diagonal brace.
Install the RH front fender upper diagonal brace
bolts (1).

Tighten
Tighten the bolts to 10 Y (89 lb in).
60. Connect the electrical connector to the headlamp.
60.1. While installing the headlamp, guide the lock
pin into the RH fender flange lock pin
retainer.
60.2. Install the headlamp bolt.

Tighten
Tighten the bolt to 2 Y (18 lb in).
60.3. Secure the inner headlamp retainer.
61. Use the scan tool to clear any existing DTCs.
62. Use the scan tool output controls to command the
Fan Relay 1, Fan Relay 2 & 3, and Fan Relays 1,2
& 3 ON and OFF. Visually inspect both of the
cooling fans for the correct ON/OFF actions when
activated. Refer to Engine Control Module Scan
Tool Output Controls in SI.

Parts Information
Part Number

Description

Qty

20899523

HARNESS ASM - ENG
COOLING FAN WRG

1

GM
P/N 19168448
Kent-Moore
P/N 12089191

CRIMP SPLICE SLEEVE
(YELLOW)

1

GM
P/N 19169142

SPLICE KIT (SEALED) (GREEN)

3

Kent-Moore
P/N 88988379

CRIMP SPLICE SLEEVE
(GREEN)

1

Warranty Information
For vehicles repaired under warranty, use:
Labor
Operation
N9620*

Labor
Time

Description
Install Revised Engine Cooling
Fan Harness and Relay
Assembly

1.8 hrs

*This is a unique labor operation for bulletin use only. It will
not be published in the Labor Time Guide.
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these
technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper
service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a
job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your
vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the
information.

WE SUPPORT VOLUNTARY
TECHNICIAN
CERTIFICATION